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A Safety Research project was carried out in an ammonia plant of OCI Nitrogen, located at the Chemelot site in Geleen, The Netherlands. This research focused on the development of a method to monitor accident processes in the chemical industry mainly caused by mechanical integrity of static equipment like vessels, tanks and heat exchangers. A significant part of the mechanical integrity failure scenarios originates from material degradation and corrosion mechanisms which may develop over a relatively long-time period, possibly taking months, years or even longer. Mechanical failure scenarios from two process units have been worked out and visualized using a bowtie. The research project shows that the monitoring of early warnings can provide information about the current development of mechanical failure scenarios. In addition, early warnings can be used to initiate inspections if there is a likelihood that the mechanical failure scenario has been activated. Considering the shift from breakdown maintenance to preventive and predictive maintenance and risk-based inspection (RBI), inspections based on early warnings could also be a new step in the field of maintenance efficiency. [ABSTRACT FROM AUTHOR]

The education and training program for inspectors of Major Accident Hazard Establishments, specifically the EC Seveso III directive implicated Dutch chemical companies, changed considerably over a fifteen year period. This longitudinal, time-series cross sectional case study describes the development of the education and training program for Major Hazard Control inspectors, acting as regulators from the Labour inspectorate, belonging to the Dutch Ministry of Social Affairs and Employment. A blueprint had to be constructed in order to assess the development and quality of this program in four cross sections over time. The description highlights both the safety related content and the regulator skills parts of the program in its changing context. Professional standards, educational objectives, quality of education, evaluation method, education change process and the response to the dynamic operational environment were examined. The main findings are that the education and training program kept the same main structure over the time period while its contents were adapted to respond to external context changes. Internal evaluation of performance data and education style led to a shift in contents from theoretical knowledge towards safety management and inspection practice oriented experience related knowledge. An active teaching style, increased usage of professional standards and more systematic evaluation, starting from the blue print in this study, offer the best opportunities for further improvement. Current insights on regulatory performance lead to a recommended future perspective for the inspectors' role to be translated into education and training: balancing empathy, inquisitiveness and support with control and enforcement, or rather: exert tough love , staying between too soft and too hard .