Functional Safety in mining
The backbone of safe, reliable operations
Functional safety in mining and bulk materials handling is not a box-ticking exercise. It is the safeguard that protects people, machines and production. For operators and maintainers on car dumpers, stackers, reclaimers and conveyors, well-engineered safety systems are the difference between smooth operation and costly incidents.
Mipac now delivers specialist machine functional safety services, built on the proven expertise of Paradigm Engineers. With more than 20 engineers trained in exida’s FSE-110 Machine Functional Safety program, and several TÜV-certified specialists, our team brings depth and precision to every stage of the safety lifecycle.
Whether you need a risk assessment of your existing systems or the full design and commissioning of a new SIL-rated safety system, we provide practical, compliant solutions that keep machines safe and productive.
Complete Functional Safety lifecycle support
Deliverables include SRS documents, safety plans, cause-and-effect charts, safety logic design, verification reports, validation test packs and proof-test procedures.
Our team delivers practical, compliant safety solutions across mining plant and machine applications.
We support the full functional safety lifecycle, including:
- Hazard and risk assessment
- SIL determination and allocation
- Safety Requirements Specification (SRS)
- Safety PLC design and software development (using the V-model)
- Verification and validation (FAT, SAT, proof testing)
- Commissioning, operation and maintenance
- Decommissioning and change management
Proven Functional Safety solutions for bulk handling in mining
3 ways we keep your operations safe
1.
Experience across every level of safety
From simple temperature monitoring to advanced emergency braking systems and safety PLCs, we’ve managed the full spectrum of functional safety requirements in bulk materials handling.
2.
Protecting people and performance
Our expertise reduces critical risks, prevents incidents and keeps your machines operating at peak performance, safeguarding both lives and productivity.
3.
Keeping you ahead of compliance
Safety standards evolve as fast as technology. We collaborate with your engineering teams to ensure every system remains functionally safe, compliant and future-ready.
Proven expertise, now part of Mipac
Our functional safety capability is built on the foundation of more than 12 years of specialist experience from the team at Paradigm Engineers, a respected name in mining and machine safety.
Mipac acquired Paradigm Engineers in early 2024, bringing together two teams with a shared focus on safety, performance and technical excellence. This integration means you now have access to a larger team of accredited functional safety professionals, with deep expertise in all aspects of the functional safety life cycle, especially in complex mining and machinery applications.
It’s the same trusted experts – now backed by Mipac’s broader engineering and project delivery capability.
Our combined Functional Safety in mining capabilities
All functional safety work is delivered by qualified engineers with experience across the relevant Australian and international standards, including:
- AS 61508 – Functional safety of electrical/electronic/programmable systems
- AS 62061 – Safety of machinery – Functional safety of safety-related control systems
- AS 4024 – Safety of machinery
- ISO 13849 – Safety of machinery – Safety-related parts of control systems
We also bring deep, practical knowledge of safety-rated platforms including Rockwell GuardLogix and Schneider M580S, with experience implementing numerous projects across major mining installations.
Our teams are also highly experienced in working with owner-operator standards, such as SEP-93, ensuring alignment with site requirements.
Proven Functional Safety solutions for major mining operations in Australia
Our engineers have delivered full-scope functional safety solutions for some of the largest mining operations in Australia, including
BHP West Australian Iron Ore
- Finucan Island Shiploaders
- Mt Whaleback/Newman Stacker
- South Flank Stackers and Reclaimer
Rio Tinto Iron Ore
- Paraburdoo Stackers
FLSmidth
- Koodaideri Stockyard Machines
These projects show what’s possible when functional safety and control system expertise are fully integrated – reducing risk and improving system performance.
Speak to a Functional Safety expert
Want to find out how functional safety applies to your site?
Our engineers can walk you through what’s required and how to approach it.
Get in touch with our functional safety team to start the conversation.
Mipac are global leaders in operational technology, control systems and engineering services.
With more than 28 years of experience, our team of engineers, project managers and solutions developers have worked on more than 720 projects. We go beyond the expected solutions to deliver:
- Advanced Process Control
- Industrial Automation, including Main Automation Contracting
- Data Analytics and Visualisation
- Process Optimisation
- Cybersecurity
- Industrial Software Solutions
- Electrical and Instrumentation
- Operations Support, inc Procurement
- Industry 4.0 Consulting
Contact us today and let’s start the conversation about how the Mipac team can bring your next project closer to achieving operational excellence.
Read more from the Mipac Insights library
Built for miners. Shaped by feedback. TCard is a software solution that’s continually evolving – because we believe the best tools are …
Mipac produces a range of software products, such as the MPA suite and TCard. Now, meet the team behind the products, from …
It’s 2 A.M. at a remote mining site. The control room operator’s screen has become a Christmas tree, multiple sensors are flashing …