MVBA System – Newcastle Safety Servicing

MVBA System –Mine Vehicle Breathing Apparatus

The Newcastle Safety Servicing Mine Vehicle Breathing Apparatus (MVBA) was created and refined for installation in heavy vehicles such as stockpile dozers where entrapment may occur due to vehicle engulfment or irrespirable atmospheres may be encountered. The system provides protection by supplying breathable air on demand to the operator for the duration of up to 6.7 hours.

The MVBA system is offered as an alternative control to Self-Contained Breathing Apparatus (SCBA) under MDG 28: Safety Requirements for Coal Stockpiles. As a standalone positive pressure system, functionality is solely mechanical not relying on machine electrical function for operation.

Functioning similar to aSelf-Contained Breathing Apparatus (SCBA) used in firefighting or confined space entry, the system negates the requirement for compressed air cylinders to be stored inside vehicle cabins.

NSS are continuing to work alongside a number of key mining partners to deliver turn-key Mine Vehicle Breathing Apparatus solutions. As part of these partnerships, NSS have been requested to supply plant and equipment that meets both legislative requirements and site-specific compliance requirements. Companies currently utilising this product include:

Newcastle Safety Servicing has carried out a comprehensive Design Risk Assessment on the Mine Vehicle Breathing Apparatus. The intent of this project was to integrate hazard identification and risk assessment methods early in the design process to eliminate or minimise the risks of injury throughout the life of the plant / equipment being designed.

The risk assessment has been carried out in accordance with processes set out in:

  • ISO12100:2010 Safety of Machinery – General principles for design – Risk assessment and risk reduction
  • AS4024 Safety of machinery Part 1201: General principles for design
  • MDG 28 Safety Requirements for Coal Stockpiles and Reclaim Tunnels.
  • Work Health and Safety Act
  • Work Health and Safety Regulation
  • Work Health and Safety (Mines and Petroleum) Act
  • Work Health and Safety (Mines and Petroleum) Regulation

One of the actions that came out of this risk assessment was to perform a semi-quantitative design review, using Failure Modes and Effects Analysis techniques, on the system in order to:

  • Identify potential failures which have unwanted effects on system operation (e.g. preclude or significantly degrade operation or affect the safety of the user),
  • Allow improvements of the system’s reliability or safety (e.g. by design modifications or quality assurance actions).

The FMEA was carried out in accordance with processes set out in AS/ISO 60812:2008 Analysis techniques for system reliability—Procedure for failure mode and effects analysis (FMEA).

Based on the outcomes of the Failure Modes and Effects Analysis, the consultative team were satisfied with the risk management process that have been applied to the MVBA and that adequate engineering controls have been identified to either eliminate or minimise the risks of equipment failure / injury to personnel.

Following the Failure Modes and Effects Analysis on theMVBA (refer to document 20190820-NSS-MVBA-Failure Modes and Effects Analysis Report 30Oct19 v3), one of the actions that came out of this risk assessment was to perform a quantitative design review, using Functional Safety Assessment techniques.

The purpose of the assessment was to:

  • Increase the safety of personnel (whilst reducing the likelihood of unplanned downtime),
  • Meet regulatory (and site-based) compliance requirements, and
  • Determine whether the safety-related control functions meet the required level of risk reduction (I.e. validate the design / determine if controls are fit-for-purpose).

The assessment was carried out in accordance with processes set out in:

  • ISO13849 Safety of machinery — Safety-related parts of control systems

As a result of conducting the FSA on the MVBA the analysis has determined that:

  • The design meets the risk reduction / performance level targets
  • The functional safety rules outlined in ISO13849 have been achieved
  • The safety requirements specification has been achieved
Furthermore, providing these safety-related control functions are installed and maintained, the MVBA will be fit-for-purpose and safe to use.

With this emergency breathing system being custom designed and installed for each individual machine, NSS can work with you to ensure all components are mounted in the most convenient location for you operators to maximise visibility.  The MVBA is currently installed on the following models of stockpile dozers:

Caterpillar: D9, D10R, D10T2, D11R, D11T, D11T2

Komatsu: D475, D375