EST. 1999

GOVERNMENT APPROVED INSPECTION AUTHORITY - LVUP 059

ENGINEERING DESIGN AND PROJECT MANAGEMENT

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;

(c)  Growth of damage in the structure as it operates; and

(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.

 

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Contact Us

RICHARDS BAY – HEAD OFFICE
Tel: +27 35 753 2245 | Cell: +27 82 376 1680 | E-mail: sl@se59.net

RICHARDS BAY
Tel: +27 35 789 1216 | Cell: +27 74 837 3463 | E-mail: ns@se59.net

DURBAN – PROSPECTON
Tel: +27 31 904 3225 | Cell: +27 83 400 4333 | E-mail: nr@se59.net

DURBAN – KZN NORTH
Tel: +27 32 944 1255 | Cell: +27 72 086 4094 | E-mail: ds@se59.net

GAUTENG
Tel: +27 11 395 3001 | Cell: +27 82 449 6827 | E-mail: jm@se59.net

ALBERTON
Cell: +27 82 823 0027 | E-mail: sy@se59.net