WMC Environment, Health & Safety Management System Specifications for New Underground Mobile Mining Underground Mobile Major Hazard Standard MHS-05 DocsOpen Ref: 57401, 03/03/1999 Uncontrolled copy check web for latest revision Revision Reviewed Description of Changes Date Approved 0 First Issue 03/03/1999 K Thomas WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.
Specifications for New Underground Mobile Mining Introduction...2 Part 1: Specifications for All Mobile Underground Mining...2 1 General Requirements...2 2 Engine Systems...2 Part 3: Site Specific Requirements... 6 Appendices... 7 A List of Australian Standards Referred to in this Document...7 3 Drive Train...3 4 Hydraulics...3 5 Pneumatic Systems...3 6 Electrical Requirements...3 7 Brakes...3 8 Lighting...4 9 Operator s Compartment...4 10 Pressure Vessels...4 11 Visibility Requirements...4 12 Reversing Alarms...4 13 Isolation Requirements...4 14 Safe Work at Heights...5 15 Documentation...5 Part 2: Additional Requirements for Certain Classes of Underground Mobile...5 1 Charge Wagons...5 1.1 Explosive Storage...5 2 Remotely Operated...5 3 Jumbos...6 4 Trucks...6 5 Loaders...6 6 Service Vehicles...6 SAF-MHS05-R01 Rev. 0 Issued: 03/03/99 Page 1 of 7
Introduction These general specifications apply to all underground mobile equipment used in the mining process. They have been developed from the EOF Standards, the statutory requirements and previous WMC documents. They are provided in a number of parts. The first part deals with requirements that apply to all UGME. Where UGME is used for a specific application and additional requirements are necessary they are listed in other parts of this specification. The general specifications do not include individual site performance requirements. These will be inserted as Part 3 of these specifications. For the purpose of these specifications underground mobile mining equipment is defined as that equipment used in the drilling, blasting, loading and transporting of ore, mullock and materials in an underground mine. It does not apply to personnel transport vehicles and light vehicles. Where compliance with any of the requirements of the specification is not practical the manufacturer or supplier must show by means of risk assessment that the alternative arrangements provide control equal to that provided by compliance with the specification. Part 1: Specifications for All Mobile Underground Mining 1 General Requirements Mobile mining equipment shall be designed and manufactured in accordance with Australian Standards relevant to the class of equipment. In addition to the above all equipment shall comply with the requirements of the WMC Resources Major Hazard Standards : Underground Mobile SAF-MHS-05 Underground Fires SAF-MHS-02 Isolation SAF-MHS-07 Safe Working at Height SAF-MHS-08. The manufacturer or supplier must show that the mobile equipment meets the requirements of all legislation in particular those pursuant to the Duty of Care of designers and suppliers. 2 Engine Systems The engine shall be provided with a management system that will automatically stop the engine and cut off the fuel in the event of the following conditions: Low engine oil pressure High coolant temperature Loss of coolant flow. The surface temperature of any part of the engine system shall not exceed 300 o C. Diesel powered engines shall have electronic controlled fuel injection. When measured at torque stall conditions without an exhaust-conditioning device installed, the engine exhaust emissions shall not contain more than: 500 ppm oxides of nitrogen 750 ppm carbon monoxide. When measured under snap load conditions the exhaust density must not exceed 40% opacity. Turbo-charged engines shall be provided with exhaust purifying devices. Provision should be made in the layout of the nonturbo-charged engines for the retrofitting of an exhaust-conditioning device if required. All hoses and pipes shall be constructed of nonflammable material. They shall be routed so that in the event of a leak or a burst, flammable liquid cannot contact a hot surface. Where this is not practical all hoses shall be securely clamped and shielded so that any burst or leak will not contact a hot surface. All pipes and or hoses shall be routed in a manner that will give them maximum physical protection and so they do not cross over electrical wiring. All low-pressure fuel lines shall be fire resistant and single wire braided hoses. Fuel filters shall have metal external surfaces. All fuel tanks shall be fitted with non-leaking caps, which are effective irrespective of the attitude of the equipment. Dry break fast fill system shall be fitted to the fuel tank. (refer site specific requirements) The engine fuel system shall be fitted with a fuel solenoid requiring power to run. The radiator is to be a non-folded steel core type. Radiator caps for cooling systems should be fitted with a means of safely relieving pressure to prevent scalding personnel. SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 2 of 7
There shall be provided in the engine compartment an automatic fire suppression system that shall: Be pressurised so that it fails safe Shuts the engine off no longer than six seconds after a pressure drop in the system. 3 Drive Train The transmission shall be a full power shift planetary type unit. It shall be capable of safe operation of grades of 1-in-5. The drive train shall be protected from impact damage by underside guards. Articulation points and drive shafts shall be protected from rock damage. The transmission shall be monitored for temperature and an over temperature warning device shall be provided in the operator s compartment. 4 Hydraulics The Manufacturer should ensure that the hydraulic systems comply with all legislative requirements and guidelines. (Refer to site specific requirements) Hydraulic hoses shall be fire resistant and meet the requirements of AS 3791. Hydraulic tanks shall be protected from impact damage. Hydraulic hoses are to be supported and or shrouded so as to eliminate wear through contact with other hoses and vehicle components. Where hoses pass through bulkheads they shall be either protected from wear by rubber grommets or have positive connection on either side of the bulkhead. Hydraulic hose fittings shall be of the o-ring quick connection type fitted in accordance with the manufacturer s recommendations. 5 Pneumatic Systems The Manufacturer should ensure that the pneumatic systems comply with all legislative requirements and guidelines. (Refer to site specific requirements). Hoses shall be fire resistant. Compressors that are driven by the engine system shall be provided with temperature monitoring devices that detect over-temperature. The devices shall provide audible warning to the operator. Where such a compressor is used to provide service air the monitoring device shall automatically stop the engine in the event of over-temperature. Where hoses pass through bulkheads they shall be either protected from wear by rubber grommets or have positive connection on either side of the bulkhead. 6 Electrical Requirements Electrical systems shall, where appropriate, comply with: All legislative requirements AS 4242 AS 2956 AS 1319 AS 3000. Where cables pass through bulkheads they shall be either protected from wear by rubber grommets or have positive connection on either side of the bulkhead. Where the cables are associated with electrical power generated by the engine system they shall be installed to AS 4242. All other cable and electrical installations shall comply with the requirements of AS 3000. All electrical circuits shall be protected against over current by circuit breakers. Strapping of electrical harnesses to hydraulic and fuel lines is not permitted. Isolation shall be provided as per SAF-MHS-07 Isolation, four pole lockable isolators shall be used. The circuitry is to be designed and installed so that the opening of the switch will stop the machine. There shall be provided a circuit breaker between the battery and the starter motor to protect against overcurrent. The battery shall be housed in a compartment that provides adequate clearance between the battery terminals and any lid. An insulating cover shall be provided on the under side of any cover which is over battery terminals. The battery compartment shall be located so that it does not form part of an access pathway or platform during maintenance. Purpose designed (refer to site specific requirements) jump-start provisions shall be provided in a location that encourages their use. 7 Brakes The brake system shall comply with the design and performance requirements of AS 2958.1. Service brakes shall be oil-cooled multiple wet discs. A gauge that indicates residual braking pressure is to be fitted in the operator s cabin. SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 3 of 7
8 Lighting The following minimum lighting shall be provided: A minimum of two high/low beam 75/70 watt, 24 volt driving lights suitably located and protected from rock fall and sidewall damage. Two 70 watt, 24 volt reverse lights suitably located and protected from rock fall and sidewall damage. Two red lights on the rear, which shall be activated when a service brake or a retarder is operated. Flashing lights, which meet the requirements as, outlined in SAF-MHS-05. 9 Operator s Compartment The internal dimensions shall meet the requirements of AS 2953. The operator s compartment shall be designed to prevent injury to the operator from: Accidental contact with sidewalls or backs, and As a minimum comply with AS 2294. A suspension seat shall be installed to reduce vibration to the lowest practical level when measured in accordance with AS 2955.6. A retractable seat belt for all persons who may ride in the vehicle shall be installed in accordance with AS 2664. The seat shall also allow the operator to be restrained by a seat belt and comfortably wear a self-rescuer and a cap lamp battery. The seat is to be adjustable (or self-compensating) for operator body weight and incorporate height and fore-aft adjustments and useable by operators in the 5th to 95th percentile as detailed in AS 2953.2. The equipment shall be designed so that it cannot be operated unless the operator is in the control position. The equipment shall designed to prevent uncontrolled movement when the engine is started. The lay out of the controls shall follow sound ergonomic principals and minimise operator fatigue. They shall as a minimum comply with the requirements of AS 2956.5 and identified in accordance with AS 2956.4. The sound level inside the operators control area shall be below 85 dba with the engine developing full power. The operator field of view shall meet the criteria specified in ISO 5006.1 Test Method ISO 5006.2 Evaluation method and ISO 5006.3 Acceptance criteria. Where necessary optical aids or other means should be provided to assist in this. Access shall meet the requirements of AS 3868 and AS 2953.1. There shall be provided two means of egress from the operator s compartment which comply with the requirements of SAF-MHS-02 and SAF-MHS-08. There shall be no sharp edges or intrusions that could cause injury to the operator from accidental contact. The cab shall be air-conditioned and the air filtered to reduce airborne contaminants to the lowest practical levels. Windscreens shall be: Laminated glass or other shatter proof material; Provided with windscreen washers, wipers and demisters. Access to external surfaces of windscreens shall comply with the requirements of SAF-MHS-08 There shall be provided two fire extinguishers, a dry powder type which is easily accessible to the operator and a foam type which is easily accessible from the ground adjacent to the refuelling point. 10 Pressure Vessels All pressure vessels shall comply with AS 1210. All vessels which store energy and as such require procedures for isolation, or discharging, prior to maintenance shall be marked with appropriate warning signs. 11 Visibility Requirements The equipment shall be provided with reflective strips on the front and rear leading edges. 12 Reversing Alarms All mobile mining equipment shall be provided with automatically activated audible reversing alarms. 13 Isolation Requirements Isolation of mobile mining equipment shall meet all aspects of SAF-MHS-07 Isolation. SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 4 of 7
14 Safe Work at Heights Where operators or maintenance personnel can fall during their normal operations, there shall be provided, suitable fixed or portable working platforms. (refer site specific requirements) Where platforms are not practical there shall be provided a safe system to carry out the work. 15 Documentation The manufacturer shall supply documentation which at the least: Allows for the development of a comprehensive operator-training programme Provides evidence of compliance with the provisions of legislative requirements Provides evidence of compliance with the provisions of this specification relative to compliance with Australian Standards and the WMC Resources Major Hazard Standards Provides evidence of compliance with the specification relative to sound levels in the operators control area Allows for the development of a comprehensive maintenance system Provides a list of critical control components as required by the provision of WMC Resources Major Hazard Standard for Underground Mobile SAF-MHS-05. Part 2: Additional Requirements for Certain Classes of Underground Mobile 1 Charge Wagons (Refer to SAF-MHS-10 Explosives) 1.1 Explosive Storage Kettles shall be located so that they are not liable to potential impact damage from uncontrolled movement of the charge wagon. Kettles shall be located so that any spillage which may occur during loading does not fall onto any electrical connections, hot surfaces, flammable fluid tanks or filling points. Storage areas for packaged explosives shall be located so that they are not liable to potential impact damage from uncontrolled movement of the charge wagon. Storage areas for packaged explosives shall be located so that a leak or spray from hydraulic cylinders and hoses cannot contact the packaged explosives. Detonators storage areas shall be separated from explosives storage areas and shall: Provide for the separation of each detonator Exclude accumulations of explosives spillage Be located so that they are not liable to potential impact damage from uncontrolled movement of the charge wagon. Positive earth straps shall be provided between any storage area and the ground. Lights shall be located so that stored explosives or detonators cannot contact them. The basket from which persons conduct the charging operations shall: Be designed following an operational risk assessment to identify the controls required for any potential hazards Be based on sound ergonomic principals Have provisions for stopping and starting the engine Have provisions for activating the fire suppression system Have provisions for emergency lowering in the event of loss of power Have provisions to prevent the operators from coming into contact with the roof 2 Remotely Operated The remote operation units shall comply with the requirements of AS 4240. Where a machine is provided with remote operating provisions the brake system shall have an emergency release system which can be remotely activated to enable towing from an unsafe area. They shall have front and rear towing points. The fire suppression system as required by Part 1 Section 2.18 of this specification shall also be capable of actuation from the operator remote control unit. A device shall be provided which automatically stops the engine and applies the brakes of the equipment if it travels to within 5 ms of the operator. Where automatic reversing lights are fitted there shall be a provision for disengaging them whilst the equipment is being remotely operated. SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 5 of 7
3 Jumbos 4 Trucks 5 Loaders 6 Service Vehicles Part 3: Site Specific Requirements Insert site specific requirements here. SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 6 of 7
Appendices A List of Australian Standards Referred to in this Document AS 1210 Pressure vessels AS 1319 Safety signs for the operating environment AS 2294 Earthmoving machinery protective structures AS 2664 Earthmoving machinery Seat belts and seat belt anchorage AS 2836 Earthmoving machinery Guidelines for access systems AS 2953 Earthmoving machinery Human dimensions AS 2953.1 Minimum access AS 2953.2 Physical dimensions of operators and minimum operator space envelope AS 2955.6 Earthmoving machinery Operator seat transmitted vibration AS 2956 Earthmoving machinery Instrumentation and operator controls AS 2956.2 Operating instrumentation AS 2956.4 Symbols AS 2958.1 Earthmoving machinery Safety: Wheeled machines Brakes AS 3000 SAA Wiring Rules AS 3791 Hydraulic Hose AS 4240 Remote controls for mining equipment AS 4242 Earthmoving machinery for use in mines Electrical wiring systems at extra low voltage Note: Equivalent ISO or other national standards apply outside of Australia Other appendices to be inserted SAF-MHS05-R01 Draft C DOCS: 57401 Issued: 03/03/99 Page 7 of 7