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

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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.