In episode 11, 'Startups & New Developments’, we welcome risk-based inspection (RBI) expert, Lynne Kaley to the show. Listen now and hear more about our small yet incredibly interconnected world of mechanical integrity professionals.

In part 1 of this two-part series, Lynne discusses her journey in the industry, starting from her early days at Amaco Oil and DNV to her contributions on the API 581 committee. This conversation highlights the various challenges and opportunities she faced throughout her career, including her transition from microbiology to metallurgical engineering, and her role in creating the principles of RBI. Lynne shares her perspective on the evolution of the industry, the importance of being proactive in solving problems, and the critical role of research and development in maintaining mechanical integrity.

Stay tuned for part 2 of our conversation with Lynne – it will be published on September 4, 2025.

00:44 Lynne's Early Career Journey

05:43 Experience in the Field and Transition to DNV

14:14 Innovative Projects and Industry Challenges

22:48 Expertise and Crack Propagation

24:37 Failure Analysis and RBI Development

25:28 Pilot Studies and Software Development

30:36 The Golden Years at DNV

38:37 Challenges and Innovations in RBI

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Episode Acronyms & Abbreviations

 581 Committee – API RP 581, Risk-Based Inspection Technology 

AE – Acoustic Emission Testing 

API – American Petroleum Institute

BRD – Base Resource Document

HIC – Hydrogen Induced Cracking

HIC-SOHIC – Hydrogen Induced Cracking-Stress Oriented Hydrogen Induced Cracking 

HTHA – High-Temperature Hydrogen Attack

JIP – Joint Industry Project

NDT – Non-Destructive Testing

PTA – Purified Terephthalic Acid

RBI – Risk-based Inspection

SOHIC - Stress Oriented Hydrogen Induced Cracking

UT – Ultrasonic Test

Wet H2S – Wet Hydrogen Sulfide

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 [email protected].

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.

The next episode with a new guest is coming on Thursday, August 21.

Here's a quick sneak peek of our conversation where you will get a taste of our lively discussion, the shared camaraderie, and potentially learn something too.  

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 [email protected].

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.

In episode 10, ‘Brilliant Whiz Kid,' Branden and Greg continue their conversation with industry legend John Reynolds. Join us as we look to the future of mechanical integrity and the integration of artificial intelligence. 

In the final part of this three-part series, listen to an in-depth discussion that starts with the application of artificial intelligence in fixed equipment mechanical integrity (FEMI) and ends with insights into the value of networking and building competency improvement plans. Once again, John Reynolds uses his extensive career to highlight the value of engaging with colleagues across the industry and within your company to help you grow professionally. Remember, your education will continue well beyond the completion of a university degree.

This was final segment of our interview with industry legend, John Reynolds. You may find part 1 “The Mountains We Still Need to Climb” and part 2 “RBI Was the Way of the Future” wherever you get your podcasts. 

00:45 AI and Big Data in Mechanical Integrity

05:58 Why Everyone Should Network

10:09 Developing Competency Improvement Plans

16:36 Participation in Process Safety & MI Audits

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Episode Acronyms & Abbreviations

AI - Artificial Intelligence

API – American Petroleum Institute

ASME – American Society of Mechanical Engineers 

FEMI – Fixed Equipment Mechanical Integrity

NACE – National Association of Corrosion Engineers, now known as AMPP (Association for Materials Protection & Performance)

NLP – Natural Language Processing

RBI – Risk-based Inspection

SCI – API Subcommittee on Inspection

SMEs – Subject Matter Experts 

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 [email protected].

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.

In episode nine, 'RBI Was the Way of the Future,' Branden and Greg continue their conversation with industry legend John Reynolds. Join us and hear about the evolution of mechanical integrity practices through John’s shared experiences and expertise. 

In part two of this three-part series, the discussion traces the history of risk-based inspection (RBI), detailing its evolution from the nuclear power sector to its codification in API 580 and API 581 standards. Discussing the early days of RBI in the 1990s, the transition from time-based and condition-based inspection to RBI's formalized process. John shares insights from his tenure as the API 581 committee chair, recounts how he advocated for the shift towards RBI to improve industry reliability and safety. This episode also touches upon the challenges inspectors face with data overload and emphasizes the need for effective data analysis to prevent major incidents.

The final episode, "Brilliant Whiz Kid" is now available, also if you missed part 1, "The Mountains We Still Need to Climb", please listen here. 

00:25 Early Days of RBI

03:35 The Evolution and Impact of Risk-Based Inspection

08:29 Challenges in Data Analysis for Inspectors

14:14 Conclusion 

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Episode Acronyms & Abbreviations

 API 580 – Risk-Based Inspection

API 581 – Risk-Based Inspection Technology

API RBI – Equity Software’s RBI desktop software available through PlantManager

CBI – Condition-based Inspection

CML – Condition Monitoring Locations

FEMI – Fixed Equipment Mechanical Integrity

MI – Mechanical Integrity

PSSAP – Process Safety Site Assessment Program

RBI – Risk-based Inspection

TBI – Time-based Inspection

TML – Thickness Monitoring Locations

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 [email protected].

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.

In episode eight, 'The Mountains We Still Need to Climb,' we welcome industry legend John Reynolds to the podcast. Join us and hear about the evolution of mechanical integrity practices through John’s shared experiences and expertise. 

In part 1 of this three-part series, John shares how he became a renowned expert in Fixed Equipment Mechanical Integrity (FEMI). Starting his career with Shell in 1968, John recounts pivotal moments including his contributions to the Inspectioneering Journal and his involvement in API standards development. He discusses the impact of major industry incidents and the evolution of standards like API 510 and 570. John also shares personal anecdotes about his love for mountain climbing and the great outdoors, how these activities have provided a balance to his professional life, and his current life in the Rocky Mountains. 

If you enjoyed this episode, make sure to listen to the rest of our interview with John Reynolds: "RBI Was the Way of the Future" (part 2) and "Brilliant Whiz Kid" (part 3). 

00:38 Meet John Reynolds

02:03 Early Career and Shell Experience

04:56 Transition to Consulting and Legal Defense

10:46 Passion for Mountain Climbing

18:00 The Three Wise Men and API Standards

30:13 Significant Industry Incidents and Lessons Learned

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Episode Acronyms & Abbreviations

API 510 – Pressure Vessel Inspection Code

API 570 – Piping Inspection Code

API 571 – Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

API 578 – Material Verification for New & Existing Assets

BSME – Bachelor of Science, Metallurgical Engineering

CMLs – Condition Monitoring Locations

FEMI – Fixed Equipment Mechanical Integrity

NDE – Non-destructive Examination 

PSSAP – Process Safety Site Assessment Program

SCIMI – Subcommittee Inspection Mechanical Integrity

TMLs – Thickness Monitoring Locations

WOSA – World Outside of America

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 [email protected].

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.

Upon Further Inspection is pleased to welcome back Andri Orphanides, API’s Director of ICP. We had such a great conversation going with Andri that we extended our chat and split her interview into two parts. Here’s part 2:

Part two of our conversation with Andri is centered around the need for developing programs and educational pathways to attract younger generations, particularly Gen Z, to the industry. She highlights the concerning trend of Gen Z's (and Gen Alpha’s) lack of interest in mechanical integrity and the challenges it poses for the future workforce. The discussion includes ideas for integrating certifications with academic degrees, creating mentorship programs, and using modern advertising methods to engage younger audiences. The discussion also touches upon the importance of mentorship programs, onboarding processes, and continual learning to foster a growth-oriented culture. Finally, you’ll get a sneak peek into some of the 2026 API Mechanical Integrity and Inspection Summit planning. NOTE – the abstract submission deadline is coming up in August!

If you missed Part 1 of our interview with Andri, listen to “Episode 6: It All Starts with the Standards” today.

00:00 Introduction 

00:37 Evolution of Inspection Practices

01:29 Addressing Workforce Challenges

03:12 Engaging the Next Generation

04:21 The Role of Certifications

10:01 Mentorship and Career Pathways

20:19 Expanding Industry Opportunities

21:27 API Mechanical Integrity & Inspection Summit 2026

24:46 Conclusion and Acknowledgements

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Episode Acronyms & ICP Certifications

API – American Petroleum Institute

Cert - Certification

ICP – Individual Certification Programs

ISO – International Organization of Standards

STEM – Science, Technology, Engineering, Mathematics

1169 – Pipeline Construction Inspector

1184 – Pipeline Facility Construction Inspector

510 – Pressure Vessel Inspector

570 – Piping Inspector

571 – Corrosion and Materials

576 – Inspection of Pressure Relieving Devices

580 – Risk Based Inspection

653 – Aboveground Storage Tank Inspector

936 – Refractory Personnel

982 – Refractory Inspector

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 [email protected].

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.

Upon Further Inspection is pleased to welcome our first podcast guest, Andri Orphanides, API’s Director of ICP. We had such a great conversation with Andri that we split her interview into two parts. 

In Episode 6, Greg, Branden, and Andri discuss her 14-year journey with API from an exam coordinator to a director. Andri shares insights into the evolution of the ICP certification programs, the career pathways they offer, and the importance of international standards. She highlights the growth from 11 to 21 API certification programs and new initiatives like the bolted joint program. The conversation also touches on industry changes, technology integration, and the importance of creating opportunities for veterans and newcomers to the field.

Part 2 "An Education Task Force", is now available wherever you get your podcasts. 

01:10 Journey into API Certification

04:31 Challenges and Growth in the Credentialing World

07:23 API Certification Numbers and Their Significance

09:50 Expanding API Certification Programs

13:40 Global Standards and Future Initiatives

23:57 Career Pathways and Opportunities

30:44 Conclusion and Closing Remarks

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Episode Acronyms & ICP Certifications

API – American Petroleum Institute

Cert - Certification

ICP – Individual Certification Programs

STEM – Science, Technology, Engineering, Mathematics

1169 – Pipeline Construction Inspector

1184 – Pipeline Facility Construction Inspector

510 – Pressure Vessel Inspector

570 – Piping Inspector

571 – Corrosion and Materials

576 – Inspection of Pressure Relieving Devices

580 – Risk Based Inspection

653 – Aboveground Storage Tank Inspector

936 – Refractory Personnel

982 – Refractory Inspector

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 [email protected].

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.

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! 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 [email protected].

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.

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! 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 [email protected].

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.

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! 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 [email protected].

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.