SAIBA Engineering – Government Approved Inspection Authority

About Us

SAIBA Engineering cc was initially established in 1999, specialising in the inspection and testing of steam generators, pressure vessels and pressurised systems and the portfolio now includes engineering design, project management and acoustic emission testing.

The company has been SANAS accredited and approved by the Department Of Labour as an inspection authority in accordance with Pressure Equipment Regulations.

100% black women owned inspection authority in South Africa.

This, together with our commitment to quality, integrity and development provides the perfect infrastructure for growth in the field of Government Inspection Authorities in South Africa and neighbouring countries.

With our team’s vast experience and our association with International Engineering Organisations and Inspection Bodies we have competent and efficient representation.

Services

AIA Manufacturing and In-Service Inspection

Steam generators
Pressure vessels
Piping
Pressurised systems
Procedure Qualification Records (PQR)
Weld Procedure Specifications (WPS)
Welder Procedure Qualifications (WPQ)
Welding consultancy

Tank and Storage Facilities

In-service and out of service inspections as per API 653 appendix C requirements
Quality Assurance on repairs and modifications as per API 650 requirements
Specialised non-destructive tests
Tank Bottom Testing Online (Acoustic Emission Testing)
Vacuum Box Testing (Integrity of floor and annular plate attachment welds)
Scorpion B-Scan Crawler. (Horizontal and Vertical magnetic crawlers for shell integrity evaluation)

Non-Destructive Testing

Ultrasonic crack detection
Radiography
Magnetic particle testing
Liquid penetrant testing
Ultrasonic thickness testing
Hardness testing
Hydro testing
Pneumatic testing
Vacuum box testing
Infrared Thermography
Acoustic Emission Testing
Scorpion B-Scan Crawler

Metallurgical Services

Weld / Parent metal failure analysis
Welding engineering (Procedures, specifications and welder qualifications)
Replicas
Mechanical destructive testing (Charpy V Notch, hot tensile, bends hardness and macro evaluations)
Chemical analysis – Spectrometric
Chemical analysis – Wet chemical

Engineering Design and Software

Pressure Vessel Design, Verification and Re-instatement to:

ASME VIII Div 1&2
PD 5500
EN 13445
EN 13458
EN 13530-2

Remaining life assessments and minimum thickness calculations

Repairs, alterations and re-rating of pressure vessels to API 510

Steam Generator Design, Verification and Re-instatement to:

BS 1113
BS 2790
EN 12952
EN 12953

Piping Design

Saiba has designed various piping systems locally and internationally which consist of Power Generating, Petrochemical, Pulp and Food Industry.

Piping stress analysis on CAESAR II software complete with 3D isometric manufacturing drawings.

ASME B31.1
ASME B31.3
ASME B31.4
ASME B31.8
EN 13480

Expansion Bellow Design and Verification

Saiba uses Bellows Master II

EJMA 10
ASME VIII
ASME 31.1
ASME 31.3

Storage Tank Design

Storage tank design to API 650 & 620
Tank repair, alterations and reconstruction to API 653

Structural steel work design and analysis with use of:

Prokon
Solidworks

3D Modeling and Finite Element Analysis

Saiba uses the following software for modeling and detailing

Solidworks
AutoCAD
Cadworks
Revit MEP

All our work is signed off by a Registered Professional Engineer.

Structural Health Monitoring

What is SHM?

SHM is the scientific process of non-destructively identifying four characteristics related to the fitness of a structure as it operates:

(a) Operational and environmental loads that act on the structure;

(b) Mechanical damage that is caused by that loading;

(d) Future performance of the structure as damage accumulates.

The acoustic emission (AE) method uniquely fits the concept of SHM due to its capabilities to periodically or continuously examine structures and assess structural integrity during their normal operation.

Acoustic Emission Testing

We are an Acoustic Emission Testing Company, which has over 12 years experience in pressure testing and other NDT methods in South Africa according to Pressure Equipment Regulations.

We incorporate the following testing standards:

BS EN 14584
ASME V, Article 11, 12, 13
BS EN 15856

Thus, we will render professional expertise with the latest technological equipment from Vallen Systeme, Germany to ensure that test results are accurate and reliable.

What is Acoustic Emission Testing?

Acoustic Emission (AE) testing is technology that exams the behavior of materials deforming under stress. AE may be defined as the spontaneous release of elastic energy when materials undergo deformation.

Basically materials "talk" when they are in trouble and AE equipment allows one to "listen" to the sounds of cracks growing and other damage in the material under stress.

Thus damage is detectable long before failure, so AE can be used to find defects during structural proof tests, plant operation or if a defect is present and AE determines if repairs are required. The test shall be conducted utilising full test load, with load being pressure, weight, temperature, current, or any combination thereof.

How does Acoustic Emission Testing work?

AE detects defects only when crack grows or secondary growth effects.
A static defect will not be detected by AE.

Acoustic Emission application examples

Pressure vessels metallic / non metallic (ASME V, article 11, 12 and 13 and BSEN 14584)

Typical Defects:

Cracks
Pits and gouges
Undercuts

Tanks (ASTM 1930-7)

Typical Defects, in both parent metal and weld associated regions:

Cracks
The effect of corrosion, including cracking of corrosion products or local yielding
Stress corrosion cracking
Certain physical changes, including yielding and dislocations
Embrittlement
Pits and gouges

In weld associated regions:

Incomplete fusion
Lack of penetration
Undercuts
Voids and porosity
Inclusions
Contamination

In parent metal:

Laminations

In brittle linings:

Cracks

High Pressure Piping (EPRI TR - 105265 - V1) 1995

Typical Defects:

Creep
Cracks
Hanger

Lifting Equipment

Typical Defects:

Cracks
Certain physical changes, including yielding and dislocations

Steam generators (EPRI TR 105265 V1) 1995 / ASME V, Article 12

Typical Defects:

Ligament cracks
Metallurgical

Transformers (IEEE)

Typical Defects:

Partial discharge
Bushings

Steam drying cylinders (ASTM E2598-7)

Typical Defects:

Cracks

Conventional vs Acoustic Emission

CONVENTIONAL TEST METHODS	ACOUSTIC TEST METHODS
Cease use and production, isolate, scaffold around area and sundry preparations. Removal of lagging and cladding, and obtain confined space permits, etc.	Minimal preparations shall be needed to test. Tests may be executed while on/off line. The above leads to a minimal effect with regard to downtime and operating loads.
NDT and visual test are required to determine integrity. The above is prone to human ability to perform these functions.	100% volumetric and scientific data; No inherent risks.
NDT / Visual tests cannot expose material weakness or fatigue cracks until the entire structure (100%) is stripped and inspected.	100% volumetric and scientific data; No inherent risks.
In these specific instances, a pressure test using air, water, or other suitable test medium may be required at the discretion of the Inspector to assess leak tightness of the pressure-retaining item. The Inspector is cautioned that a pressure test will not provide any indication of the amount of remaining service life or the future reliability of a pressure-retaining item. REF: NBIC: Part 2: 4.3.1.(B)	AE is a complete and effective tool for the accurate measurement of structural integrity via the break-through of modern science.
All manual reporting of defects and condition of structure as supplied by inspection and NDT companies.	Scientific reporting as per international standards.
Non accessible locations are not inspected.	Data obtained on all stressed parts irrespective of the inaccessibility.
Inspection and testing as per the requirements and standards set by PER and (NBIC).	Testing conducted in accordance with Asme V, Article 12,BSEN 14584,and various Astm and EPRI standards. Testing methods, equipment, personal shall be audited annually.
No accurate measure/method to control the risk of explosion during pneumatic testing.	Online monitoring of structural integrity during pneumatic testing, giving a full and accurate report of the findings and determining the test termination by both measuring deflection and energy emitted.
Current PER requires an inert medium for pressurising during pneumatic testing.	AET standards permits pressurising with product being LPG (BSEN 12819:2009)
Visual testing and limited NDT are the only tests available for non metallic structures.	Highly recommended by the testing standards for non-metallic structures due to the nature of AET method (Asme V, Article 11)
It is not intended to inhibit or limit the use of other evaluation methods. It is recognised that acoustic emission and fracture mechanics are acceptable techniques for assessing structural integrity of vessels. Analysis by fracture mechanics may be used to assess the structural integrity of vessels when complete removal of all ammonia stress cracks is not practical. If alternative methods are used, the above recommendation that all cracks be removed, even fine cracks may not apply.	Verified by NBIC for NH3 vessels REF: NBIC: Part 2: 2.3.6.4.(6)

Disadvantages of Acoustic Emission Testing?

None growing discontinuities may not generate AE.
Subsequent application of load to the previous applied maximum stress level will only identify discontinuities which are still active.
It is sensitive to in-service or other extraneous noise.