Find that Needle in the Haystack (featuring Terry McLane)

Find that Needle in the Haystack (featuring Terry McLane)

We welcome Terry McLane, a veteran inspector with deep roots in refining, back to the podcast for part 2 of our discussion. In this candid conversation, the guys cover the full spectrum of mechanical integrity (MI) from technology to program fundamentals to the realities of field work.  Terry weighs in on where tools like guided wave and acoustic emission fall short, and why drones, robotics, phased array, and automated ultrasonic testing (AUT) represent the more meaningful advances worth watching. A central theme throughout is the role of non-intrusive inspection in reducing turnaround surprises — and what it means when discovery is still driving scope growth.  Terry shares the importance of corrosion control documents (CCDs), risk-based inspection (RB)I, and integrity operating windows (IOWs) and how he prioritizes them. He tackles CML placement and optimization, makes the case for radiographic testing on small-diameter piping, and discusses how strong inspector-operator relationships and practical training are often the difference between a program that works on paper and one that works in the field. Terry also addresses the business side of MI: how to document the value of inspection work, use deferrals responsibly, and make the case for budget when outcomes are hard to quantify. He shares real-world damage finds from his career and speaks to a few particular inspection challenges found in high-consequence units.  Whether you're managing an MI program, working inspections day-to-day, or trying to make smarter technology decisions, this episode offers grounded perspective from someone who has seen it all from the field up.  If you missed Part 1 of our interview with Terry, you can listen here [https://www.buzzsprout.com/2489029/episodes/19326480]. Remember to subscribe to Upon Further Inspection and get notified when all future episodes are published.  00:00 Tech Hype Question 00:30 Guided Wave Limits 00:54 Acoustic Emission Reality Check 02:33 Drones for Inspection 03:29 Non-Intrusive Inspection Matures 06:42 IOWs and Operator Communication 09:34 CCDs as Inspector Playbook 13:33 RBI CCD IOW Priority 14:19 CML Overload and Optimization 16:19 RT for Small Bore Piping 17:50 Proving ROI With Saves 20:54 Winning Budget Justifications 23:37 RBI in Turnaround Decisions 25:33 Deferrals and Due Diligence 26:48 Escalating Deferral Decisions 28:02 Writing Procedures and Training 28:57 PowerPoint Pictures and Stories 31:08 HF Alky Inspection Burden 32:31 HF vs Sulfuric Debate 33:58 Favorite Damage Finds 35:41 Coker Corrosion Close Calls 39:36 Future of Mechanical Integrity 42:33 Gratitude Family and Mentors   Episode Acronyms & Abbreviations AI – Authorized Inspector through the National Board of Boiler & Pressure Vessels API – American Petroleum Institute CML – Condition Monitoring Locations HF Alky – Hydrofluoric Acid Alkylation Unit RBI – Risk-based Inspection RT – Radiographic Inspection 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.

We're Not in the Business of Making Cookies (featuring Terry McLane)

In this episode, we sit down with Terry McLane, a veteran refinery inspector with over 44 years of experience. Terry shares his journey from a plumbing and pipefitting apprentice into refinery maintenance contractor, and ultimately into a full-time career as an inspector. Terry speaks to the value of professional certifications and reflects on his 15 years contributing to API's Individual Certification Program (ICP), where he develops and reviews exam questions with a focus on fairness and practical relevance to the industry. This episode is really focused on how to build strong inspectors. Terry outlines a development path rooted in NDT fundamentals, radiographic film interpretation, welding inspection, and a progressive approach to certifications — always tailored to the individual's strengths and interests. He emphasizes that a solid grounding in metallurgy and damage mechanisms is non-negotiable, and that newer technologies like phased-array UT and Risk-Based Inspection (RBI) are reshaping what inspectors need to know. Terry also shares several field experiences that illustrate the real-world stakes of inspection work, including cases involving hydrogen blistering severe enough to require vessel replacement, and a situation where he exercised his authority to shut down an FCC unit after identifying a critical integrity concern on a reactor riser line.  Part 2 of our interview with Terry will be published on June 25 – subscribe to our podcast to be notified when the next episode is published.  00:37 Plumber to Refinery 02:58 Work Ethic Lessons 03:38 Switching to Inspection 05:36 AI Exam vs API Tests 07:30 Why Certifications Matter 08:09 Inside the ICP 09:13 Fair Test Questions 13:01 Training New Inspectors 15:55 Metallurgy in the Field 18:06 Learning from Old Timers 19:09 Old-School UT Stories 21:16 Tools vs Operator Skill 21:22 High Temp UT Technique 22:07 Telltale Holes Explained 26:28 Hydrogen Blister Horror Story 28:25 Inspection Tech Evolution 32:10 FCC Inspector Prestige 35:48 Regulators and Audits 38:40 Shutdown Authority Story   Episode Acronyms & Abbreviations API – American Petroleum Institute API 510 – Pressure Vessel Inspection Code API 570 – Piping Inspection Code API 580 – Elements of a Risk-based Inspection (RBI) program API 650 – Welded Tanks for Oil Storage API 653 – Tank Inspection, Repair, Alteration, and Reconstruction CWI – Certified Welding Instructor EPA – Environmental Protection Agency (US Government Agency) FCC – Fluid Catalytic Cracking ICP – Individual Certification Program (API) ITEP – Industrial Tax Exemption Program National Board – refers to the National Board of Boiler & Pressure Vessel, Pressure Equipment Inspector Certification Program NDT – Non-destructive Testing OSHA - Occupational Safety and Health Administration PAUT – Phased Array Ultrasonic Testing PTFE – Polytetrafluoroethylene coating RBI – Risk-based Inspection UT – Ultrasonic Testing VPP – Voluntary Protection Plan 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.

Toughest Damage Mechanisms Don't Give Advanced Warnings (featuring Chad Patschke)

Chad Patschke is back on the podcast to discuss the toughest damage mechanisms in refining and chemical industries. Based on his years of process safety expertise, he emphasizes that the toughest damage mechanisms offer very little warning like HTHA, corrosion under insulation (CUI), and buried piping/soil-to-air interfaces. There are many pros and cons of using drones, robotics, and artificial intelligence (AI) in your inspections; however, Chad warns that these technologies can create an overwhelming amount of data and should never replace human judgment guided by field experience, process knowledge, and IOW exceedances. They address audit findings around insufficient data analysis, managing mountains of data, and using RBI as ongoing surveillance to detect “snakes in the grass.”  Chad explains barriers to CML optimization, especially liability fears, and stresses documented management systems, cross-functional buy-in, defensibility, and root-cause focus when leaks occur. Building on his pragmatic approach to PSM audits, Chad shares several concerns about the increase in incidents since COVID, recommending that as an industry we need to work together to re-instill the importance of process safety in younger personnel.  Take a listen to a pragmatic approach to mechanical integrity that builds on Chad’s lessons learned after decades of conducting field audits.   If you missed Part 1 “Don’t Compromise on these Pillars of Mechanical Integrity [https://www.buzzsprout.com/2489029/episodes/19173362]”, listen today on uponfurtherinspection.com [https://www.buzzsprout.com/2489029/episodes/19173362].  00:00 Damage Mechanisms That Surprise 01:33 CUI Funding and Execution 02:30 Buried Piping Blind Spots 03:07 Drones AI And Human Judgment 04:48 Data Overload and RBI Surveillance 06:37 CML Optimization and Liability Fear 09:59 Defensible Decisions After Leaks 13:07 Making DMR IOWs Actually Work 15:06 Shared Ownership NASCAR Model 16:31 Respect for Process and COVID Effects 21:25 Life at ETHOS And Pragmatic Audits 24:36 Picture of the Week Origin Story 26:24 Travel Fatigue and Hotel Routine 27:34 Life on the Road Balance 28:03 Contract Negotiation Headaches 28:51 Leaping into Entrepreneurship 29:49 Consulting Advice and Ethics 31:45 Communicating Findings Respectfully 32:43 APM Systems and Benchmarking 38:29 Data Migration and Cleanup Reality 41:54 NDE Data Quality and Vetting 43:13 How Audits Really Start 45:40 Best and Worst Site Assessments 46:56 Workbench Wisdom Right Tools   Episode Acronyms & Abbreviations API – American Petroleum Institute API 571 – Corrosion and Materials API 751 – Safe Operation of Hydrofluoric Acid Alkylation Units  CMLs – Corrosion Monitoring Locations CUI – Corrosion Under Insulation DMR – Damage Mechanism Review HTHA – High-Temperature Hydrogen Attack IDMS – Inspection Data Management System IOW – Integrity Operating Windows NDE – Non-Destructive Evaluation OFI – Opportunities for Improvement (part of the PSSAP) PSSAP – API’s Process Safety Site Assessment Program PPE – Personal Protective Equipment 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.

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.