Upon Further Inspection
Upon Further Inspection is a mechanical integrity podcast that celebrates the people, stories, and real-world industrial reliability experiences. Through engaging interviews, it explores topics relevant to professionals in oil & gas, refining, petrochemical, and other process industries. Discussions cover continuous improvement, safety, technology advancements, compliance, risk-based inspection, and professional growth.
Episodes
Steering the Ship, Not Rowing the Oars (featuring Ryan Corn)
In Part 1 of our conversation with Ryan Corn, Lead Corporate Refining Reliability Specialist at Marathon, hosts Branden Stucky and Greg Alvarado trace Ryan’s path from pre-med classes in small-town Illinois to a career in mechanical integrity. Ryan shares how his experience in quality and process engineering at a glass stovetop manufacturer and later managing a machine shop that repaired pipeline
Where the Rubber Meets the Road (featuring Kelly Schupp)
We're back with Kelly Schupp, ASME PCC Standards Chair and Consulting Engineer at Equity, for part 2 of our conversation! This episode picks up with Kelly’s transition from design engineering to refinery and chemical plant fixed equipment, including how an all-day interview at Valero changed her career direction, a “sink or swim” introduction to post-construction, and lessons in writing techn
When You Know Better, You Do Better (featuring Kelly Schupp)
In this episode, we sit down with Kelly Schupp, ASME PCC Standards Chair and Consulting Engineer at Equity, to dive into the world of Post Construction Code. Kelly takes us behind the scenes of PCC-1, PCC-2, and PCC-3, explaining why PCC-1 dropped “Guidelines for” from its title, what makes flange criticality ranking so challenging, and where facilities can improve their approach to flange assembl
I Found My Passion in Corrosion (featuring Abdulrahman Al-Rumaidh)
We are pleased to welcome Abdulrahman Al-Rumaidh, a senior corrosion engineer from Bahrain to the podcast! Hosts, Greg Alvarado and Branden Stucky, learn about his path from mechanical engineering at the University of Bahrain into fixed equipment inspection and corrosion. He describes early influences like materials science and rigorous report writing, internships in upstream operations and shipya
API Summit - The Gray Beards Panel Continues (featuring Ray Konet, John Reynolds, and Clay White)
Recorded live in person from the 2026 API Inspection and Mechanical Integrity Summit in San Antonio, this episode picks up where the "Graybeards" panel, a conference session that was held earlier that morning, left off. Hosts Greg and Branden sit back down with Ray Konet, John Reynolds, and Clay White to work through the attendee questions that didn't make it into the live session.T
No Coasting, All Brake, All Gas (Featuring Melanie Brewer)
In Part 2 of our conversation with Melanie Brewer, MI Authority at Third Coast, hosts Branden and Greg dig into the practical realities of standing up a mechanical integrity program in a startup-like midstream environment. After nearly 30 years at a single facility, Melanie made the deliberate move to Third Coast specifically for the challenge and opportunity of building an MI and reliability prog
API Summit - Thoughts from the Show Floor (featuring Andri Orphanides)
Inside the 2026 Inspection & Mechanical Integrity Summit… Recorded live in person from the 2026 Inspection and Mechanical Integrity Summit in San Antonio. Andri Orphanides joins our hosts Greg and Branden to talk about planning the 10th Edition of the API Summit over two years, adding new elements like the Energy Exchange, petrochemical track, digital transformation content, charity golf tourn
How a ChemE Got into Mechanical Integrity (featuring Melanie Brewer)
In this episode of Upon Further Inspection, Branden and Greg sit down with Melanie Brewer, MI Authority at Third Coast and a 20-plus-year veteran of the mechanical integrity space. Melanie traces her unexpected path from aspiring aerospace engineer — inspired by the NASA programs of the 1980s — to chemical engineering at the University of Dayton, where a co-op program gave her real-world exposure
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, phase
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 Cer
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 in
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
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,
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 outp
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 discuss
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 supervisin
Why Some RBI Programs Fail While Others Flourish
In this episode of Upon Further Inspection, we explore the most common missteps and best practices in RBI implementation, examining what separates programs that deliver lasting value from those that fall short. The discussion highlights the importance of defining clear goals before selecting technology, building a culture where risk-based language is spoken at every level of the organization, and
Metal Wants to Return to Its Simple Form (featuring Lionel Roberts)
In part 1 of our interview with Lionel Roberts, he reflects on his early career at Canadian refineries, where limited resources and mentorship pushed him to think creatively and build a strong professional network.The conversation delves into Lionel's experiences at independent refineries without access to major company resources, highlighting how he leveraged industry organizations like NACE
Plans Are Worthless, but Planning Is Everything
In this episode of Upon Further Inspection, we explore the challenges and best practices for optimizing enterprise asset management systems while maintaining high availability and safety performance. The discussion highlights the importance of designing digital frameworks around organizational needs, supported by strong processes such as RBI, root cause analysis, and MOC programs, along with clear
Episode 20 - Year in Review
In the 20th episode, we mark a significant milestone, reflecting on our past guests and their diverse insights. We express gratitude to our guests and their employers for the invaluable conversations that have helped broaden the podcast’s scope, including Andri Orphanides, John Reynolds, Lynne Kaley, Bobby Wright, Clay White, and Alexander Gonzalez. We highlight the importance of networking, commu
Episode 19 - From Transition to Transformation (featuring Alexander Gonzalez)
In part 2 of our interview with Alex Gonzalez, we dive into the challenges and opportunities of implementing mechanical integrity programs in modern facilities. Alex shares his experiences rolling out RBI and inspection management platforms across an enterprise, discussing the critical importance of breaking down organizational silos and securing executive buy-in for successful implementation.The
Episode 18 - From Tropics to Tundra (featuring Alexander Gonzalez)
In part 1 of our interview, we welcome Alex Gonzalez, an asset performance management specialist with extensive experience in the mechanical integrity field. Alex traces his career from his studies in materials engineering and metallurgy in Venezuela through his current work in Canada's oil and gas sector. The discussion covers his focus on corrosion science, the role political circumstances
Episode 17 - Hope & Luck Are Not a Strategy for Success (featuring Bill Valerioti)
Part 2 of our interview with Bill Valerioti, a semi-retired petrochemicals and chemical industry SME, is now available! We dive right in with an interesting comparison between the chemical and refining industries. Bill draws on his extensive experience to emphasize the abundance of information available in refining compared to the more secretive nature of chemical manufacturing. Bill also contrast
Episode 16 - Fell in Love with Materials Engineering (featuring Bill Valerioti)
We have a deep dive into materials engineering and corrosion this time around! In part 1 of our interview, we welcome Bill Valerioti, a semi-retired petrochemicals and chemical industry SME. From his early days in chemical engineering to finding his passion for materials engineering and corrosion – Bill shares insight into his passion for materials failure analysis, mechanical integrity, and chemi
Episode 15 - Getting a Good DMR (featuring Clay White)
We’re excited to welcome Clay White to the podcast!In this episode, Clay shares personal experiences and incidents that fueled his dedication to improving industry safety standards. He reflects on historical events, including the polypropylene reactor leak, and how these shaped his approach to safety. The conversation explores challenges in data management, the critical role of Damage Mechanism Re
Episode 14 - Stood the Test of Time (featuring Clay White)
Welcome to the world of mechanical integrity! In part 1 of our interview, we welcome Clay White to the podcast. Take a listen as Clay takes us through his career journey, from earning a welding and metallurgy degree to becoming a recognized expert in mechanical integrity, corrosion, and materials engineering – including his contributions to API 581. Our discussion explores the evolution of Risk-Ba
Episode 13 - On a Cat Cracker During a Tornado (featuring Bobby Wright)
In Episode 13, we are pleased to welcome industry veteran Bobby Wright to the podcast! From his beginnings working summers on an assembly line in Arkansas to becoming a business strategist and mentor, Bobby shares the valuable lessons learned and experiences that shaped his path. He discusses pivotal moments, including his roles at refineries and handling emergencies, like tornadoes. Key highlight
Episode 12 - We're Over-Inspecting (featuring Lynne Kaley)
Part 2 of our interview with Lynne Kaley is now live. In episode 12, ‘We’re Over-Inspecting’, we welcome risk-based inspection (RBI) expert, Lynne Kaley back to the show. Listen now and hear more about our small yet incredibly interconnected world of mechanical integrity professionals. Branden, Greg, and Lynne discuss the significant shift in the mechanical integrity industry over the years and ho
Episode 11 - Startups & New Developments (featuring Lynne Kaley)
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
Teaser! When was API 571 first published?
Here's a sneak peek of our conversation with Lynne Kaley. You will get a taste of our lively discussion, the shared camaraderie, and potentially learn something too. Send a text & tell us what you think!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
Episode 10 - Brilliant Whiz Kid (featuring John Reynolds)
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 inte
Episode 9 - RBI Was the Way of the Future (featuring John Reynolds)
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 n
Episode 8 - The Mountains We Still Need to Climb (featuring John Reynolds)
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 S
Episode 7 - An Education Task Force (featuring Andri Orphanides)
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 in
Episode 6 - It All Starts With the Standards (featuring Andri Orphanides)
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 care
Episode 5 - Boilers Were Blowing Up
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
Episode 4 - Gotta Document Logic
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 impor
Episode 3 - Secrets Behind HIC-SOHIC
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 1980
Episode 2 - The Missing Piece was Metallurgy
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 technolo
Episode 1 - What Floats Your Boat
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, environ
