Record Keeping and Competence After a Near Miss
You are the shotfirer at a quarry. During a recent blast, a near miss occurred: a detonator was found unexploded on the muckpile after the blast. The detonator was from a batch that had been stored in the magazine for 2 years. The magazine records show that the batch was received on 1 January 2022 and the current date is 1 January 2024. The magazine temperature log shows that the temperature has been maintained between 5°C and 25°C. The detonator was a non-electric detonator with a 20 ms delay. The blast used 50 detonators from that batch. The shotfirer has 10 years of experience but no formal qualification. The site's record-keeping procedure requires that all explosives are recorded on receipt, issue, and use, and that any malfunctions are reported. The near miss was not reported to the regulator. The shotfirer's assistant, who is new, was responsible for loading that hole.
1. What record-keeping deficiencies are evident, and what actions should be taken to rectify them?
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The record-keeping deficiencies include: the near miss was not reported to the regulator, which is a legal requirement under explosives regulations. The magazine records may not have been properly maintained; the batch was stored for 2 years, which may exceed the recommended shelf life for some detonators, and there is no record of stock rotation or inspection. The issue and use records should show which detonators were used in which holes, but it appears the unexploded detonator was not accounted for. The shotfirer's assistant loaded the hole, but there is no record of who loaded which hole or of the assistant's training. The shotfirer lacks formal qualification, which may be a competence issue. To rectify, the shotfirer should immediately report the near miss to the regulator and the site management. A full investigation should be conducted to determine why the detonator failed to initiate. All records should be reviewed and updated: ensure that each detonator is tracked by serial number, that stock is rotated (first in, first out), and that expired stock is segregated. The shotfirer should implement a daily magazine inspection log. The assistant should receive proper training and supervision. The shotfirer should obtain formal qualification if required. The site should review its record-keeping procedure to ensure compliance with legislation.
2. How would you address the competence and communication issues highlighted by this incident?
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The competence issues include the shotfirer lacking formal qualification despite 10 years of experience, and the new assistant being responsible for loading without adequate supervision. The shotfirer should undergo formal training and certification as required by law (e.g., Shotfirer's Certificate). The assistant should be trained in safe handling of explosives and supervised until competent. Communication issues: the near miss was not reported, indicating a poor safety culture. The shotfirer should establish a clear reporting procedure and encourage near-miss reporting without blame. Regular toolbox talks should be held to discuss hazards and procedures. The shotfirer should also ensure that the blast plan is communicated to all crew, and that roles and responsibilities are clear. The assistant should be paired with an experienced mentor. The shotfirer should review the loading procedure to ensure that detonators are checked before use and that any anomalies are reported. Additionally, the shotfirer should consider implementing a buddy system for loading. The site should conduct a competency assessment for all blasting personnel. Finally, the shotfirer should document the actions taken and monitor effectiveness.