Meeting the challenges related to material issues in chemical industries

Reliable performance and profitability are two important requirements for a ny chemical industry. In order to achieve high level of reliability and exc ellent performance, several issues related to design, materials selection, fabrication, quality assurance, transport, storage, inputs from condition m onitoring, failure analysis etc. have to be adequately addressed and implem ented. Technology related to nondestructive testing and monitoring of the p lant is also essential for precise identification of defect sites and to ta ke appropriate remedial decision regarding repair, replacement or modificat ion of process conditions. The interdisciplinary holistic approach enhances the life of critical engineering components in chemical plants. Further, u nderstanding the failure modes of the components through the analysis of fa iled components throws light on the choice of appropriate preventive measur es to be taken well in advance, to have a control over the overall health o f the plant. The failure analysis also leads to better design modification and condition monitoring methodologies, for the next generation components and plants. At the Indira Gandhi Centre for Atomic Research (IGCAR), Kalpak kam, a unique combination of the expertise in design, materials selection, fabrication, NDT development, condition monitoring, life prediction and fai lure analysis exists to obtain desired results for achieving high levels of reliability and performance assessment of critical engineering components in chemical industries. Case studies related to design, materials selection and fabrication aspects of critical components in nuclear fuel reprocessin g plants, NDT development and condition monitoring of various components of nuclear power plants, and important failure investigations on critical eng ineering components in chemical and allied industries are discussed in this paper. Future directions are identified and planned approaches are briefly described.