In this episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado discuss the evolution of mechanical integrity, exploring its transition from past practices to our current standards and regulations. They recount a couple historical failures (the Union Oil Lemont refinery explosion in 1984 and the Shell Norco explosion in 1988) that highlight the importance of developing stringent inspection codes. 

The discussion touches upon the role of standards, the shift from localized to holistic thinking, the integration of technology, and the critical importance of mentoring and the role of generalists in the industry.  The hosts conclude this episode with some advice for new engineers – be passionate about your work, seek to understand the link between data and wisdom, and ask guidance from experienced mentors.

00:00 Introduction to Mechanical Integrity Podcast

02:08 Historical Events Shaping Mechanical Integrity

04:47 Evolution of Codes and Standards

08:59 Understanding Recommended Practices vs. Standards

12:28 Regulatory Bodies and Their Roles

17:31 Boiler Inspections and Heat Treatment

25:19 Technological Advancements in PMI

28:06 Evolution of Mechanical Integrity Programs

29:06 The Role of Generalists and Specialists

33:12 Challenges in Implementing Predictive Models

44:24 Advice for New Asset Integrity Engineers

48:35 Conclusion and Final Thoughts 

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Episode Acronyms & Abbreviations

• 1910.119 - OSHA's process safety management of highly hazardous chemicals
• ANSI - American National Standards Institute (USA)
• API - American Petroleum Institute (USA)
  • RP - recommended practice
• ASME - American Society of Mechanical Engineers (USA)
• ERP - enterprise resource planning software
• FEA - finite element analysis
• LNG - liquid natural gas
• NACE - National Association of Corrosion Engineers (now called AMPP - the Association for Materials Protection & Performance, USA)
• NBIC - National Board Inspection Code (USA)
• OSHA - Occupational Health & Safety Administration (USA)
• P&IDs - piping and instrumentation diagram
• PMI - positive materials identification
• RBI - risk-based inspection (API RP 581)
• SME - subject matter expert

Thank you for listening to Upon Further Inspection!

We'd love to hear from you! Please follow us on LinkedIn and share your feedback on the latest episode. If you have suggestions for future topics or guests, please email inspectionpodcast@gmail.com.

Please join us next time wherever you listen to your podcasts. Until then, stay safe and stay informed.

Note: this podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado discuss the concepts of qualitative and quantitative Risk-Based Inspection (RBI). 

They talk about the history of the API 581 RBI project from the early 1990s and explore how the methodologies have evolved from qualitative to quantitative approaches. The conversation highlights the benefits of both methods, the importance of systematic documentation, and the role of advancing technology in improving inspection processes. Key topics include the development of risk management tools, the transition from hand calculations to computer-based models, and the impact of RBI on damage mechanism reviews and corrosion control.

00:00 Introduction to Mechanical Integrity Podcast

00:20 Hosts Introduction and Episode Overview

00:52 Qualitative vs Quantitative RBI

01:18 Historical Context of RBI Development

03:59 Evolution of RBI and Technological Advances

06:48 Impact of RBI on Industry Practices

08:33 Documentation and Software in RBI

09:42 Future of RBI and AI Integration

12:25 Closing Remarks and Podcast Credits 

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Episode Acronyms & Abbreviations

• API - American Petroleum Institute
• CCDs - corrosion control documents
• CML - corrosion monitoring locations
• IDMS - inspection data management system
• IOWs - integrity operating windows
• JIP - joint industry project
• NDE - non-destructive examination (or evaluation)
• RBI - risk-based inspection
• TML - thickness management locations

Thank you for listening to Upon Further Inspection!

We'd love to hear from you! Please follow us on LinkedIn and share your feedback on the latest episode. If you have suggestions for future topics or guests, please email inspectionpodcast@gmail.com.

Please join us next time wherever you listen to your podcasts. Until then, stay safe and stay informed.

Note: this podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In Episode 3 of Upon Further Inspection, co-host Greg Alvarado continues to share stories of his career and experiences, particularly focusing on his time with DNV and the significant projects he was involved in. The episode covers detailed case studies on Hydrogen Induced Cracking (HIC) and Stress-Oriented Hydrogen Induced Cracking (SOHIC), including breakthrough practices and tests from the 1980s and 1990s. The discussion also touches on advancements in automated ultrasonic testing (UT) and the progression of metallurgical lab work to understand and mitigate material failures in the industry.

00:00 Introduction to Mechanical Integrity Podcast

00:22 Greg's Background and Early Career

01:25 Industry Burst Tests and HIC-SOHIC Insights

03:22 DNV Projects and HTHA Discoveries

06:10 Automated UT and Technological Advances

11:41 Pioneering Work and Industry Collaborations

16:57 Concluding Remarks and Credits 

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Episode Acronyms & Abbreviations

• AE Test - acoustic emission testing
• HIC - hydrogen induced cracking
• HTHA - high-temperature hydrogen attack
• MAWP - minimum allowable working pressure
• NDE - non-destructive evaluation (or examination)
• PSA - pressure swing adsorption
• SOHIC - stress-oriented hydrogen induced cracking
• UT - ultrasonic testing 
  • AUT = automated ultrasonic testing

Thank you for listening to Upon Further Inspection!

We'd love to hear from you! Please follow us on LinkedIn and share your feedback on the latest episode. If you have suggestions for future topics or guests, please email inspectionpodcast@gmail.com.

Please join us next time wherever you listen to your podcasts. Until then, stay safe and stay informed.

Note: this podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, Branden asks Greg about his extensive career in mechanical integrity and reliability, starting as a chief chemist at Dutch Boy Paints to becoming a key figure at Monsanto, DNV, and finally, at Equity Engineering. 

Throughout the episode, Greg discusses his passion for chemistry and metallurgy, the evolution of risk-based inspection (RBI), and the technological advancements in non-destructive evaluation (NDE). He shares insights on the importance of mentoring, the integration of safety, environment, and profitability in the industry, and the educational mission behind Inspectioneering. Greg’s experience is so varied and extensive that we had to divide up his introduction into two parts, listen to episode three for the next chapter in Greg’s history. 

00:00 Introduction to the Mechanical Integrity Podcast

00:45 Greg's Background and Career Beginnings

01:47 Transition to Monsanto and Early Career Challenges

05:05 Learning and Mentorship at Monsanto

14:19 The Evolution of Mechanical Integrity and RBI

23:28 Navigating Regulatory Challenges and Industry Changes

26:43 Regulator Types and Early Career Moves

27:47 Developing the Lotus Tool and Founding Inspectioneering

29:21 Educating the Industry and Regulator Training

34:45 Return to DNV and the Rise of RBI

38:45 Equity Engineering and Industry Collaborations

45:31 Exploring IT and Software in the Industry

47:36 Reflecting on Inspectioneering's Impact and Future Goals

49:14 Podcast Goals and Future Discussions

54:13 Conclusion and Credits 

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Episode Acronyms & Abbreviations:

• ABSA - Alberta Boiler Safety Association (Canada)
• API - American Petroleum Institute 
• API RBI - Equity Software RBI software product
• ASME - American Society of Mechanical Engineers (USA)
• BRD - base resource document
• CML - condition monitoring locations
• HTHA - high-temperature hydrogen attack
• NDE - non-destructive examination (or evaluation)
• QA/QC - quality assurance & quality control
• OSHA - Occupational Safety & Health Administration (USA)
  • Cal OSHA - California OSHA (see above)
• PSM - process safety management
  • 29 CFR 1910.119 - PSM standard for highly hazardous chemicals
• RBI - risk-based inspection (API 581 code)
• SAGE - Equity Software fitness-for-service software product (SagePlus)
• UT - ultrasonic testing

Thank you for listening to Upon Further Inspection!

We'd love to hear from you! Please follow us on LinkedIn and share your feedback on the latest episode. If you have suggestions for future topics or guests, please email inspectionpodcast@gmail.com.

Please join us next time wherever you listen to your podcasts. Until then, stay safe and stay informed.

Note: this podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In the inaugural episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado kick things off with a conversation about their journeys in mechanical integrity and why this podcast exists. 

From the power of mentorship to the future of technology, they chat about what’s shaping the reliability and inspection world. They also explore how the industry continues to balance safety, environmental responsibility, and profitability. It’s an honest, insightful start to a series built on sharing knowledge and elevating the people behind the work.

00:00 Introduction to the Podcast

00:41 Meet the Hosts: Branden and Greg

02:04 Branden's Journey into Mechanical Integrity

07:27 The Role of Technology in Mechanical Integrity

10:41 Challenges and Future of the Industry

18:23 Goals and Vision for the Podcast

31:21 Conclusion and Final Thoughts 

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Episode Acronyms & Abbreviations

• API - American Petroleum Institute (USA)
• CML - condition monitoring locations
• ERP - enterprise resource planning
• OSHA - Occupational Safety & Health Administration (USA)
• PSM - process safety management (USA)
• RBI - risk-based inspection
• ROI - return on investment

Thank you for listening to Upon Further Inspection!

We'd love to hear from you! Please follow us on LinkedIn and share your feedback on the latest episode. If you have suggestions for future topics or guests, please email inspectionpodcast@gmail.com.

Please join us next time wherever you listen to your podcasts. Until then, stay safe and stay informed.

Note: this podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.