Upon Further Inspection

Don’t Compromise on these Pillars of Mechanical Integrity (featuring Chad Patschke)

“Office of the Week” guy, Chad Patschke, joins the hosts of Upon Further Inspection to share stories and insights from his 30+ year career in process safety and mechanical integrity (MI). Starting in 1992 with early Process Safety Management (PSM) rollout as a plant engineer, Chad discusses how the industry has shifted from a “bare minimum compliance” philosophy to valuing robust MI programs.  He reminisces about the challenge of convincing management to invest in prevention and the cyclical corporate attitude of cost-cutting followed by renewed standards after a major incident.  Chad emphasizes the importance of implementing sustainable, well-documented management systems and evergreening key tools like damage mechanism reviews, integrity operating windows (IOWs), and risk-based inspection (RBI) to improve near-miss learning and data analysis. Finally, in a special recognition to two previous UFI guests, Chad recognizes the value of his life-long mentors, John Reynolds and Mark Bell. Listen now for advice and valuable lessons in how to navigate the constantly evolving landscape of industrial safety.   1:30 Career Origins in PSM 05:02 From Plants to Consulting 07:11 PSM Culture Shift 11:01 Selling Safety to Management 16:56 The Industry Sine Wave 18:52 Building Sustainable MI Systems 22:22 PSM Maturity Across Industries 26:42 Audit Experience Worldwide 29:38 IOW and Damage Mechanisms 31:09 From CMLs to DMRs 32:39 NASCAR Program Analogy 35:04 Building Ownership Culture 37:50 Process Over People 44:07 AI for Data Insights 46:46 Evergreening MI Programs 49:41 80 20 Compliance Focus 55:10 Mentors Who Shaped Me   Episode Acronyms & Abbreviations AFPM – American Fuel & Petrochemical Manufacturers AIChE – American Institute of Chemical Engineers API – American Petroleum Institute API 751 – Safe Operation of Hydrofluoric Acid Alkylation Units CCD – Corrosion Control Documents CCPS – Center for Chemical Process Safety (non-profit within AIChE) CMLs – Corrosion Monitoring Locations CSB – US Chemical Safety & Hazard Investigation Board DMR – Damage Mechanism Review EPA – US Environmental Protection Agency IDMS – Inspection Data Management System IOW – Integrity Operating Windows MI – Mechanical Integrity NDE – Non-Destructive Evaluation OSHA – Occupational Safety and Health Administration PSM – Process Safety Management RBI – Risk-based Inspection  Send a text & tell us what you think! [https://www.buzzsprout.com/2489029/fan_mail/new] Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.   We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at inspectionpodcast@gmail.com [inspectionpodcast@gmail.com]. Join us next time, wherever you get your podcasts. Until then, stay safe and stay informed. Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Feeding the Beast (featuring Mark Bell)

Upon Further Inspection welcomes Mark Bell back to the podcast with Part 2 of our discussion where he shares stories and insights from his decades of inspection and mechanical integrity experience.  As a member of the API/AFPM site assessment program, he has performed assessments and PSM audits across many companies. He highlights gaps he sees in smaller facilities: limited adoption of CCDs, IOWs, and effective RBI/IDMS use, often letting budgets drive wrong inspection techniques (e.g., spot UT instead of needed radiography). He recounts a 1988 explosion and other cases to stress how localized corrosion and unknown damage mechanisms can have catastrophic consequences, and argues for proactive corrosion engineers, field presence, mentoring, and a culture that rewards conservative shutdown decisions. He cautions that AI/RBI are only as good as their inputs and ownership. Listen now for practical, experience-based guidance on improving mechanical integrity and preventing repeat failures. If you missed part 1 “From Boilermaker to Expert”, please listen here [https://www.buzzsprout.com/2489029/episodes/18985065]. 00:39 Why Sites Must Share 01:09 Joining API APM Audits 04:44 Assessment Takeaways 05:41 Lessons from Site Explosion 10:04 Modern Tools CCD IOW 12:03 Mentors Who Shaped Me 16:31 Building A Strong Program 18:43 Budget Versus Right NDE 25:13 Spot UT Limits and Future 29:51 Corrosion Monitoring Debate 31:02 Credible Damage Mechanisms 33:02 CCDs Into Inspection Plans 34:29 Culture and Recognition 37:05 Hard Calls on Leaks 41:33 Field Communication Matters 43:11 AI Needs Good Data 45:09 RBI Garbage In, Garbage Out 49:31 RBI Horror Stories 52:24 Ownership Over Tools   Episode Acronyms & Abbreviations AP – American Petroleum Industry AFPM – American Fuel & Petrochemical Manufacturers CCDs – Corrosion Control Documents CMLs – Corrosion Monitoring Locations DMRs – Damage Mechanism Reviews IDMS – Inspection Data Management Systems IOWs – Integrity Operating Windows MOC – Management of Change PSM – Process Safety Management RBI – Risk-based Inspection RT – Radiographic Testing UT – Ultrasonic Testing Send a text & tell us what you think! [https://www.buzzsprout.com/2489029/fan_mail/new] Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.   We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at inspectionpodcast@gmail.com [inspectionpodcast@gmail.com]. Join us next time, wherever you get your podcasts. Until then, stay safe and stay informed. Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

From Boilermaker to Expert (featuring Mark Bell)

In this episode we welcome Mark Bell, a semi-retired fixed equipment consultant to the podcast. The animated discussion between Greg, Branden, and Mark provide a practical, experience-based look at how great inspectors are developed and how inspection quality is improved over time. Mark’s key takeaway is that effective mechanical integrity depends less on “having certifications” or flashy NDE outputs and more on disciplined learning, sound decision-making, qualified people, and repeatable data—especially for something as basic as UT thickness readings. He explains how mentorship, clear procedures, verification/testing of technician capability, and consistent practices (including global standardization and technical networks) can dramatically raise both the quality and usefulness of inspection data, helping plants move away from “hope is not a plan” toward reliable, trendable integrity decisions. 01:36 From Boilermaker to Inspector 05:16 Mentorship and Learning Culture 07:01 Decision Making as Inspector 08:37 Early NDE Tools and RT Focus 12:27 Picking Locations and Intervals 14:00 Three Wise Men Document 17:58 School and Career Motivation 21:13 API 510 Origins and First Test 23:21 Certifications Change the Role 24:34 Certs Versus Competence 25:45 Early Welding and NDE Exams 27:42 Spotting Fake Credentials 29:37 NDE Tech Evolution 32:07 PAUT Versus TOFD 35:20 Explaining Results to Management 36:30 Qualification and Performance Testing 38:45 Better Thickness Data 42:24 CML Trending Strategy 44:26 Using All the Data 46:18 Averaging to Reduce Error 49:57 Global Best Practices at Shell 54:26 Tech Networks and Productivity   Episode Acronyms & Abbreviations API 510 – Pressure Vessel Inspection Code API 570 – Piping Inspection Code & Inspector Certification API 571 – Damage Mechanisms Affecting Fixed Equipment API 653 – Tank Inspection, Repair, Alteration, & Reconstruction CML – Corrosion Monitoring Locations CWI – Certified welding inspector EP – Engineering practice EPRI – Electric Power Research Institute IDMS – Inspection Data Management Systems MFE – Multi-flow Evaluator NDE – Non-Destructive Evaluation PAUT – Phased Array Ultrasonic Testing RT – Radiographic Testing SFI – Slurry fracture injection TML – Thickness Monitoring Locations TOFD – Time of Flight Diffraction Technique UT – Ultrasonic Testing  Send a text & tell us what you think! [https://www.buzzsprout.com/2489029/fan_mail/new] Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.   We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at inspectionpodcast@gmail.com [inspectionpodcast@gmail.com]. Join us next time, wherever you get your podcasts. Until then, stay safe and stay informed. Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Codes, Committees, and Critical Thinking (featuring Brent Ray)

In part 2 of our conversation with Brent Ray, we take a deeper look at his extensive work with industry codes and standards through API, ASME, and NBIC. Brent reflects on how reviewing a marked up draft of API 571 in 2003 helped launch a path that later included chairing API 581, API 580, the Subcommittee on Inspection and Mechanical Integrity, and the API Inspection Summit. Throughout the discussion, he discusses the challenge of writing standards that are both technically sound and accessible, and offers advice to young engineers trying to make sense of complex and overlapping guidance. Brent also gives listeners an inside look at the 10th API Inspection Summit coming to San Antonio in July 2026, including new divisions, expanded training, a charity golf tournament, and the much-anticipated “Gray Beards” panel. He shares candid career wisdom on navigating emerging standards like ASME Section 5 Subsection C, the challenge of bridging NBIC and fitness-for-service communities, and what he hopes his legacy will be: the engineer’s engineer. Whether you are active in codes and standards work, preparing to attend your first API Inspection Summit, or simply looking to strengthen your technical foundation, Brent's perspective offers valuable lessons on leadership, communication, and what it means to serve the broader industry.  Subscribe today so you don't miss our next episode! If you missed part 1 "Curiosity, Caves, & Carbon Steel", you can listen here [https://www.buzzsprout.com/2489029/episodes/18829394]. * 00:00  Introduction and API engagement origins * 00:49  Brent’s early history with codes and standards * 02:55  First API meeting experience  * 05:39  Chairing API 581 and saving it from sunset * 07:07  ASME PCC involvement and API subcommittee leadership * 07:50  API Inspection Summit chair role and cross-industry communication * 10:35  NBIC, state boiler inspectors, and the evolving role of fitness for service * 13:52  ASME Section 5 Subsection C — new in-service NDE rules explained * 18:38  Advice for young engineers navigating codes and standards * 22:27  Critical thinking, connecting the dots, and avoiding hasty conclusions * 25:19  Quick glossary: API 578, API 751, ASME PCC 1/2/3, PTB-2 * 29:36  API Inspection Summit 10th anniversary preview — San Antonio, July 2026 * 38:35  Career edification and taking one nugget a day from Summit * 41:15  Wildest process units: FCC catalyst and the Cuming unit explosion * 43:48  Career legacy — the engineer’s engineer * 45:36  Conclusion and podcast credits +++++++++++ Episode Acronyms & Abbreviations * AI — Artificial Intelligence * AMPP — Association for Materials Protection and Performance * API — American Petroleum Institute * APM — Asset Performance Management * ASME — American Society of Mechanical Engineers * EAP — Enterprise Asset Performance * FCC — Fluid Catalytic Cracking * HF Alky — Hydrofluoric Acid Alkylation * KPI — Key Performance Indicator * MI — Mechanical Integrity * NACE — National Association of Corrosion Engineers * NBIC — National Board Inspection Code * NDE — Nondestructive Examination * PCC — Post-Construction Committee (ASME) * PTB — Pressure Technical Bulletin (ASME) * RBI — Risk-Based Inspection * SCIMI — Subcommittee on Inspection and Mechanical Integrity (API) * TNT — Trinitrotoluene Send a text & tell us what you think! [https://www.buzzsprout.com/2489029/fan_mail/new] Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.   We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at inspectionpodcast@gmail.com [inspectionpodcast@gmail.com]. Join us next time, wherever you get your podcasts. Until then, stay safe and stay informed. Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Curiosity, Caves, and Carbon Steel (featuring Brent Ray)

In part 1 of our interview with Brent Ray, Fixed Equipment & Mechanical Integrity Specialist at Marathon Petroleum, we explore the experiences and influences that helped shape his engineering perspective. After opening with a pair of gripping spelunking stories, Brent traces a career path guided by curiosity and opportunity—from studying materials science and chemical engineering to supervising melt operations and eventually joining Marathon in 2002 as a corrosion and metallurgical engineer. The conversation explores how his background in metallurgy gave him a fundamental understanding of why metals behave the way they do, and how that insight continues to guide his work addressing corrosion, damage mechanisms, and equipment reliability in refinery environments. We also discuss the importance of breaking down silos between fixed equipment, inspection, maintenance, operations, and tech service, and what it looks like when that culture of communication actually takes root. Whether you are early in your engineering career, managing a team of inspectors, or simply enjoy a good story about scrap metal and Levi’s rivets, Brent’s reflections offer thoughtful perspectives on curiosity, mentorship, and the importance of understanding how materials are actually made.  Part 2 of our interview with Brent Ray is now available, you may listen here [https://www.buzzsprout.com/2489029/episodes/18917812]. * 00:00  Introduction and Spelunking Stories * 08:02  Growing Up in West Virginia and University of Kentucky * 11:02  Career at Inco Alloys / Special Metals * 14:26  Enron’s Ripple Effect on American Industry * 19:28  Engineering Degrees and Mentor Dr. George Crew * 20:21  Lessons from the Steel Mill  * 23:05  The Levi’s Button Contamination Story * 27:32  How the Steel Mill Prepared Him for Refinery Work * 33:17  Transition from Steel Mill to Refinery / Joining Marathon * 39:21  Mindset Shift: Seeing Process from the Outside In * 41:13  Think Like an Inspector * 46:12  Critical Thinking, Curiosity, and Mentoring Young Engineers * 47:39  Breaking Down Silos  * 52:13  Cultural Shift: Communication, Adaptability, and the "Easy Button" * 56:30  Sense of Family at Marathon and in the Industry +++++++++++ Episode Acronyms & Abbreviations * ASME - American Society of Mechanical Engineers * ASTM - American Society for Testing and Materials * DRI - Direct Reduced Iron * FEMI - Fixed Equipment Mechanical Integrity * MI - Mechanical Integrity * MOC - Management of Change * MT - Magnetic Particle Testing * NDE - Nondestructive Examination * PMI - Positive Material Identification * PT - Liquid Penetrant Testing * RBI - Risk-Based Inspection * RCM - Reliability Centered Maintenance * RP - Recommended Practice * RT - Radiographic Testing * SME - Subject Matter Expert * SOHIC - Stress Oriented Hydrogen Induced Cracking +++++++++++ Send a text & tell us what you think! [https://www.buzzsprout.com/2489029/fan_mail/new] Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.   We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at inspectionpodcast@gmail.com [inspectionpodcast@gmail.com]. Join us next time, wherever you get your podcasts. Until then, stay safe and stay informed. Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.