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. 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
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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.
