Gregory Alvarado

Gregory Alvarado is responsible for business development and strategic planning for metallurgy, reliability, corrosion, inspection, and FFS consulting services, software, and technology for chemical, refining, and petrochemical facilities.  Areas of technical expertise include damage mechanism identification, shutdown work scope reviews using risk-based inspection techniques, materials selection, and group strategizing facilitation with a focus on strategies for existing/aging equipment.  Other areas of expertise include evaluation of NDE techniques for finding expected damage, mechanical integrity audits, inspection benchmarking, and development and maintenance of engineering standards. 

Gregory is a senior consultant with over 45 years of experience in the chemical and refinery industries, having served as a senior member of Monsanto’s materials engineering group at the J.F. Queeny plant in St. Louis and as chief chemist for NL industries.  He has specialized in risk-based inspection training and project management.  He is a 37-year member of the API subcommittee on inspection, a working member of the API group that created the recommended practice for risk-based inspection (RP 580 and 581), and a member of the API team preparing test questions for refinery damage mechanisms (API RP 571) and inspector endorsements (API RP 580).  

Gregory provides technical support and NDE consulting for all levels of chemical and refinery technical experts and management.  He also had extensive experience in preparation and delivery of training courses and technical presentations and has taught numerous industry-related courses to practicing engineers and technicians.  He has extensive experience working at plants and with central engineering globally.

Awards:

• American Petroleum Institute, Service Recognition for Contributions to API RP 580 and 581
• American Petroleum Institute, Service Recognition for 35 Years of Service
• Various Recognitions for Papers, Workshops, and Presentations on RBI, Inspection Planning, FFS, and IOWs at/from:
  • IPEIA – multiple including a Piping Integrity Workshop
  • NACE – various
  • API – various on advanced NDE, RBI, inspection strategies, and planning
  • Nagoya University, Nagoya, Japan
  • American Society of Non-Destructive Testing
  • National Petroleum & Refiners Association
  • American Fuels and Petrochemical Manufacturers Association
  • International Chemical and Petroleum Industry
  • Risk Forum, The Society of Non-Traditional Technology (SNTT) Tokyo
  • ASME – various
  • Mary Kay O’Connor Process Safety Symposium on Risk-Based Inspection
  • ESOPE
  • Asset Management Integrity Summits – Abu Dhabi, KSA, Bahrain

Publications:

1. Alvarado, G., “Whiteboard Discussion: Damage Mechanism Review (DMR) Considerations,” Inspectioneering, video, January 22, 2024.
2. Alvarado, G., “Announcing Our Newest Editorial Board Member: George Williamson, PE,” Inspectioneering, blog, October 26, 2023.
3. Alvarado, G., “Solving the Mechanical Integrity & Reliability Sustainability Program Puzzle,” Inspectioneering Journal, September/October 2023 Issue.
4. Alvarado, G., “Safety and Profit – Can They Coexist?” Inspectioneering, blog, August 31, 2023.
5. Alvarado, G., “Without Proper Context, Your Ladder May Be Leaning Against the Wrong Building,” Inspectioneering Journal, blog, April 27, 2023.
6. Alvarado, G., “Beware the Snare of Confirmation Bias,” Inspectioneering, blog, December 29, 2022.
7. Alvarado, G., “Highlights from Inspectioneering’s 2022 Editorial Board Meeting,” Inspectioneering, blog, June 30, 2022.
8. Alvarado, G., “Some Things are Immutable,” Inspectioneering, blog, February 24, 2022.
9. Alvarado, G., “Overcoming Pitfalls When Establishing an Effective RBI Program,” Inspectioneering Journal, September/October 2021 Issue.
10. Alvarado, G., “Highlights from Inspectioneering’s Latest Editorial Board Meeting,” Inspectioneering, blog, June 30, 2021.
11. Alvarado, G., “Should Auld Acquaintance Be Forgot? A Look Back at Two of Inspectioneering’s Most Popular Topics from 2020, Inspectioneering, blog, March 1, 2021.
12. Alvarado, G., “RBI Pitfalls to Avoid and Helpful Advice,” Inspectioneering Journal, September/October 2020 Issue. 
13. Alvarado, G., “Inspectioneering Journal Turns 25 – How it all began,” Inspectioneering, blog, February 27, 2020.
14. Alvarado, G., “There’s Gold in Those Damage Mechanism Reviews – Leveraging More Value from DMRs,” Inspectioneering Journal, September/October 2019 Issue.
15. Alvarado, G., “Make 2019 the Year You Improve the “Data Fidelity” of Your Inspection Program,” Inspectioneering Journal, January/February 2019 Issue.
16. Alvarado, G., “RBI Lessons Learned – Common and Not So Common Pitfalls and How to Avoid Them, “Inspectioneering Journal, November/December 2018 Issue.
17. Alvarado, G., “Quality Assurance – Inspection Strategy Execution,” Inspectioneering Journal, July/August 2018 Issue.
18. Alvarado, G., “Establishing the Right Mindset as Industry Seeks Improved Performance – An Important Challenge as We Move into 2018,” Inspectioneering Journal, January/February 2018 Issue. 
19. Nyholt, J. and Alvarado, G., “Connecting the Proper Inspection Strategies to Damage Mechanisms,” Inspectioneering Journal, November/December 2017 Issue.
20. Alvarado, G., “Establishing Risk Thresholds or Targets for RBI,” Inspectioneering Journal, July/August 2017 Issue. 
21. Alvarado, G., “Executive Q&A with Clay White, Director of Mechanical Integrity for Phillips 66,” Inspectioneering Journal, March/April 2017 Issue.
22. Alvarado, G., “Whiteboard Discussion: A Fundamental RBI Metric,” Inspectioneering, video, March 24, 2017.
23. Alvarado, G., “2017’s Leadership “To Do List” – Business Processes and their Importance,” Inspectioneering Journal, January/February 2017 Issue.
24. Alvarado, G., “Whiteboard Discussion: Foundational Principles of Risk-Based Inspection,” Inspectioneering, video, February 17, 2017.
25. Alvarado, G., “RBI, Inspection Effectiveness and Human Factors,” Inspectioneering Journal, November/December 2016 Issue.
26. Alvarado, G., “The Importance of People, Processes & Risk Based Inspection,” Inspectioneering Journal, September/October 2016 Issue.
27. Alvarado, G., “Why RBI? 6 Reasons to Start Your RBI Program Today,” Inspectioneering, blog, July 15, 2016.
28. Alvarado, G., “2015 is behind us – Let’s Look Ahead,” Inspectioneering Journal, January/February 2016 Issue.
29. Alvarado, G., “Effective End of Useful Life Strategies for Pressure Equipment,” Inspectioneering Journal, July/August 2015 Issue. 
30. Alvarado, G., “Enable Successful Turnarounds with These 8 Tips for Taking Advantage of Today’s Technology,” Inspectioneering, blog, March 2, 2015.
31. Alvarado, G., “2014 – A Retrospective – Time to Work Even Smarter,” Inspectioneering Journal, January/February 2015 Issue.
32. Alvarado, G., “Design Stage Risk-based Inspection (RBI) – Can it be done?” Inspectioneering, blog, February 9, 2015.
33. Alvarado, G. and Nichols, M., “Key Performance Indicators – Understanding is Key,” Inspectioneering Journal, November/December 2014 Issue. 
34. Alvarado, G., “Situation Awareness: Making Mobile Technology Work for You,” Inspectioneering, blog, October 27, 2014.
35. Alvarado, G., “Situation Awareness and Crude Unit Turnaround Work Execution,” Inspectioneering, blog, September 18, 2014.
36. Alvarado, G., “What Is Situation Awareness (SA) and How Can It Improve My Job?” Inspectioneering, blog, August 25, 2014.
37. Alvarado, G., “Acoustic Emission Monitoring for HIC-Affected Vessels,” Inspectioneering, blog, May 5, 2014.
38. Alvarado, G., “The Importance of Generic Failure Frequencies in RBI Technology,” Inspectioneering, blog, April 21, 2014.
39. Alvarado, G., “Three Approaches for Non-Intrusive Inspection of Spheres – How Effective is the Strategy?” Inspectioneering, blog, March 17, 2014.
40. Alvarado, G., “Tips on Establishing an Inspection Strategy for a Fertilizer Plant,” Inspectioneering, blog, March 3, 2014.
41. Alvarado, G., “Reflecting on Asset Integrity Management in 2013 and Looking Forward to 2014,” Inspectioneering, blog, January 27, 2014.
42. Alvarado, G., “Industry Remembers the Life and Contributions of Trevor Kletz,” Inspectioneering Journal, November/December 2013 Issue.
43. Alvarado, G., “API 571, 577, and 580 are now individual, standalone certifications,” Inspectioneering, blog, November 18, 2013.
44. Alvarado, G., “Conclusions on Scalable Accuracy,” Inspectioneering, blog, September 9, 2013.
45. Alvarado, G., “Scalable Accuracy for Risk-Based Inspection,” Inspectioneering, blog, September 3, 2013.
46. Alvarado, G., “Fitness for Service (FFS) using Scalable Accuracy,” Inspectioneering, blog, August 26, 2013.
47. Alvarado, G., “The Scalable Accuracy Approach to Equipment Lifecycle Management,” Inspectioneering, blog, August 19, 2013.
48. Alvarado, G., “Making the Case for Scalable Accuracy,” Inspectioneering, blog, August 12, 2013.
49. Alvarado, G., “In Follow Up to the Inspectioneering Journal Article on Hydrogen Bake-Outs,” Inspectioneering, blog, July 29, 2013.
50. Alvarado, G., “Thoughts on Father’s Day,” Inspectioneering, blog, June 17, 2013.
51. Alvarado, G., “Uncertainty, RBI Risk Thresholds, and Damage Factor Targets,” Inspectioneering, blog, June 10, 2013.
52. Alvarado, G., “Understanding and Managing Risk,” Inspectioneering, blog, June 3, 2013.
53. Alvarado, G., “RBI: Defining Risk (COF/POF),” Inspectioneering, May 28, 2013.
54. Alvarado, G., “RBI: A short history and justification,” Inspectioneering, blog, May 20, 2013.
55. Alvarado, G., “Understanding Key Performance Indicators (Lest We Forget…) – Part 3,” Inspectioneering, blog, May 13, 2013.
56. Alvarado, G., “Update on our AIM Benchmarking Survey,” Inspectioneering, blog, May 6, 2013.
57. Alvarado, G., “Understanding Key Performance Indicators (Lest We Forget…) – Part 2,” Inspectioneering, blog, April 29, 2013.
58. Alvarado, G., “Understanding Key Performance Indicators (Lest We Forget…) – Part 1,” Inspectioneering, blog, April 22, 2013.
59. Alvarado, G., “Why do we inspect?” Inspectioneering, blog, March 3, 2013.
60. Alvarado, G., “Integrity Management Programs, KPIs and PSM Lest We Forget…,” Inspectioneering Journal, March/April 2013 Issue.
61. Alvarado, G., “The Value of Mentors in Inspection and Materials Engineering,” Inspectioneering, blog, February 25, 2013.
62. Alvarado, G., “2012 in Review – Growing Value, Expanding Content, Leveraging Synergies,” Inspectioneering Journal, January/February 2013 Issue. 
63. Alvarado, G., “Risk Based Inspection – Setting Risk Targets,” Inspectioneering Journal, July/August 2012 Issue.
64. Alvarado, G., “Integrity Management and the Oil and Gas Shale Plays,” Inspectioneering Journal, May/June 2012 Issue.
65. Alvarado, G., “Scalable Accuracy: Inspection Planning and RBI,” Inspectioneering Journal, January/February 2012 Issue.
66. Alvarado, G., “More On Scalable Accuracy,” Inspectioneering Journal, November/December 2011 Issue. 
67. Alvarado, G., “INSPECTION OF UNDERGROUND PIPING EPRI Update on Nuclear Power Plant Activities,” Inspectioneering Journal, September/October 2011 Issue. 
68. Alvarado, G., “Scalable Accuracy,” Inspectioneering Journal, March/April 2011 Issue.
69. Alvarado, G., “Learning From the Past: Not Letting the Pendulum Swing to the Opposite Extreme in Our Mechanical Integrity Programs – Part 2,” Inspectioneering Journal, November/December 2008 Issue.
70. Alvarado, G., “Learning from the Past: Not Letting the Pendulum Swing to the Opposite Extreme in Our Mechanical Integrity Programs – Part 1,” Inspectioneering Journal, September/October 2008 Issue.
71. Alvarado, G., “Interview with Scot Haines, Hess Corporation Fixed Equipment Reliability Coordinator,” Inspectioneering Journal, July/August 2008 Issue. 
72. Alvarado, G., “You Don’t Get Something for Nothing – Risk-Based Inspection – The significant problems we face cannot be solved from the same level of thinking at which they were created,”  Inspectioneering Journal, May/June 2008 Issue.
73. Alvarado, G., “API 2008 Spring Refining Meeting – API RBI Base Resource Document Meetings Debut,” Inspectioneering Journal, March/April 2008 Issue.
74. Alvarado, G., “Risk Based Inspection – The Regulatory Acceptance Process,” Inspectioneering Journal, November/December 2007 Issue.
75. Alvarado, G., “Where Do I Set My Risk Threshold?” Inspectioneering Journal, September/October 2007 Issue.
76. Alvarado, G., “Don’t Overlook the Value: Questions and Answers from the Inspectioneering Discussion Forum,” Inspectioneering Journal, September/October 2007 Issue.
77. Alvarado, G., “In Memory of John Dunlop McMillan: 1945 – 2007,” Inspectioneering Journal, September/October 2007 Issue.
78. Alvarado, G., “Risk-Based Inspection: Utilizing Metrics, Maximizing the Value,” Inspectioneering Journal, May/June 2007 Issue. 
79. Alvarado, G., “Risk-Based Inspection – How Healthy is Your RBI Program?” Inspectioneering Journal, March/April 2007 Issue.
80. Alvarado, G., “Risk-Based Inspection Case of Histories (Part 1 of 2): An Interview with Sean Johnson, Pressure Equipment Integrity Assurance Engineer for the Shell Martinez, CA Refinery,” Inspectioneering Journal, July/August 2006 Issue.
81. Alvarado, G., “IJ 2006 Survey Preliminary Results,” Inspectioneering Journal, January/February 2006 Issue. 
82. Alvarado, G., “The Inspectioneering Journal Marks 10 Year Anniversary,” Inspectioneering Journal, March/April 2005 Issue.
83. Alvarado, G., “Interview with John Nyholt – BP NDE Specialist,” Inspectioneering Journal, September/October 2004 Issue.
84. Alvarado, G., “Staying on Track in a Complex Environment – Equipment Reliability and Life Cycle Cost Minimization,” Inspectioneering Journal, July/August 2004 Issue.
85. Alvarado, G., “Considering Buying Linked Inspection Database Management and RBI Programs?” Inspectioneering Journal, March/April 2004 Issue.
86. Alvarado, G., “RBI – Eliminating Misconceptions and Misapplications,” Inspectioneering Journal, March/April 2004 Issue. 
87. Alvarado, G. (invited participant and contributor), New Forces at Work in Refining, RAND Corporation for the National Energy Technology Laboratory and the US DOE, 2003.
88. Alvarado, G., “More Than Low Hanging Fruit – Reaping a Greater Harvest – RBI and Step Change,” Inspectioneering Journal, July/August 2003 Issue. 
89. Alvarado, G., “Risk Based Inspection (RBI) Impact of Inspection – Past, Present and Future,” Inspectioneering,” May/June 2003 Issue.
90. Al-Marzouqi, M. and Alvarado, G., “Risk Based Inspection Implementation – LNG Plant,” Inspectioneering Journal, March/April 2003 Issue.
91. Alvarado, G., “Canadian Province Issues Minimum Requirements for RBI,” Inspectioneering Journal, November/December 2002 Issue.
92. Alvarado, G., “Interview with John Nyholt, BP NDE Specialist,” Inspectioneering Journal, September/October 2002 Issue.
93. Hsiao, C.P. and Alvarado, G., “NDE Input to Fitness for Service Decision Making – Part 2,” Inspectioneering Journal, May/June 2002 Issue.
94. Hsiao, C.P. and Alvarado, G., “NDE Input to Fitness for Service Decision-Making – Part 1,” Inspectioneering Journal, January/February 2002 Issue.
95. Alvarado, G., “The Growing Importance of Understanding NDE Applications and Results,” Inspectioneering Journal, November/December 2001 Issue.
96. Alvarado, G., “Evolution of the Equipment Integrity Process – The Current Benchmark – Part 2,” Inspectioneering Journal, September/October 2001 Issue.
97. Alvarado, G., “Evolution of the Equipment Integrity Process – The Current Benchmark – Part 1,” Inspectioneering Journal, July/August 2001 Issue.
98. Alvarado, G., “Interview with Dr. David Wang – Primary NDE Researcher,” Inspectioneering Journal, July/August 2001 Issue.
99. Alvarado, G., “Profile on AGIP Refinery Inspection Department-Livorno, Italy,” Inspectioneering Journal, November/December 2000 Issue.
100. Alvarado, G., “RBI Simpler is Better – Part 2,” Inspectioneering Journal, September/October 2000 Issue.
101. Alvarado, G., “RBI Simpler is Better – Part 1,” Inspectioneering Journal, July/August 2000 Issue.
102.       Alvarado, G., “Risk Based Inspection (RBI) – The Current State – Part 2,” Inspectioneering Journal, November/December 1999 Issue.
103. Alvarado, G., “Risk Based Inspection (RBI) – The Current State – Part 1,” Inspectioneering Journal, September/October 1999 Issue.
104. Alvarado, G., “Food for Thought – Risk Based Inspection (RBI),” Inspectioneering Journal, September/October 1998 Issue.
105. Barringer, P. and Alvarado, G., “Risk Based Inspection and Regulatory Compliance – They Can Co-Exist,” Inspectioneering Journal, September/October 1998 Issue.
106. Alvarado, G., “Inadequate Inspection Documentation Cited in One of Four Root Causes In 1995 Explosion – “Repair mention does not an inspection make!”,” Inspectioneering Journal, May/June 1998 Issue.
107. Alvarado, G., “Risk Based Inspection – Understandings and Expectations,” Inspectioneering Journal, January/February 1998 Issue.
108. Alvarado, G., “Risk Based Inspection (RBI) – What’s Best for You? – Know Your Objectives & Look for Substance!” Inspectioneering Journal, September/October 1997 Issue.
109. Alvarado, G., “What’s the Connection between RCM and RBI?” Inspectioneering Journal, March/April 1997 Issue. 
110. Alvarado, G., “Committee Reports, Recommended Practices (RP’s) & Standards of Benefit to Inspectors, Engineers & Managers,” Inspectioneering Journal, September/October 1996 Issue.
111.      Alvarado, G., “Tips for Successful Contracting of NDE Services,” Inspectioneering Journal, March/April 1996 Issue. 
112.      Alvarado, G. and Wang, W., “Methods for Detection, Characterization & Quantification of High Temperature Hydrogen Attack – Improved Cost-effectiveness and Reliability,” Inspectioneering Journal, November/December 1995 Issue.
113.     Alvarado, G., “Inspection of Glass-Lined Equipment – A Refresher,” Inspectioneering Journal, September/October 1995 Issue. 
114.       Alvarado, G., “So You are Considering On-Stream Inspection Technologies… Have You Thought it Through? – Part 1: Automated Ultrasonics and Environmentally Assisted Damage,” Inspectioneering Journal, July/August 1995 Issue.
115.       Alvarado, G., “Back to Basics: Keys to establishment of an effective inspection program,” Inspectioneering Journal, May/June 1995 Issue. 
116.       Alvarado, G., “Begin With the End in Mind – Want to get over the hump?” Inspectioneering Journal, March/April 1995 Issue.
117. Alvarado, G., “Welcome to the First Issue of the Inspectioneering Journal,” Inspectioneering Journal, March/April 1995 Issue.

Conference & Training Presentations:

1. “Understanding API RP 581: Risk-Based Inspection,” presented by G. Alvarado for Inspectioneering.