As part of their quest to reduce the number of reported industrial incidents, plant operators and official bodies are focussing extensively on regulations and compliance to do everything they can to eliminate the risk of potentially serious incidents occurring. However, if an incident does occur it is crucial for all staff to have the skills and knowledge required to understand and handle the outcome of an accident. Training is key here and this is where the challenge lies: How can organisations replicate real-world situations, without actually releasing hazardous agents into the environment?