Development of HSE Technical Training Elements in the Fertilizer Division of EuroChem MCC JSC

From Theory to Practical Skills: Why Production Needs Training Grounds

Mandatory legislative occupational safety training provides basic knowledge but often leaves gaps in real practical skills (hard skills). The speaker explains why companies need to transition to the format of training grounds to reduce injuries and prevent equipment breakdowns. Using the example of the Fertilizer Division of EuroChem MCC JSC, the process of creating technical training centers is shown, where employees practice hands-on actions before entering actual production.

Architecture of HSE Technical Training

The presentation details the approach to equipping classrooms and training grounds. The equipment must closely match what is installed in the workshops. This avoids the effect of being "disconnected from reality."

• Modularity and increasing scenario complexity. Training is built from simple to complex: from working at ground level to simulating emergency situations (e.g., loss of consciousness in a confined space). This forms a stable skill of acting in stressful situations.
• Integration of procedures into basic processes. Lockout/Tagout (LOTO) elements are not just studied separately but are integrated into mechanical and power engineering programs. The employee gets used to applying lockout devices as an integral part of pump repair or work in electrical installations.
• Checklist assessment. Transitioning from subjective evaluation to measurable criteria. Using checklists allows standardizing exams and making the process transparent for both staff employees and contractors.

Objective Filter for Contractors

Special attention is paid to testing the knowledge of contractor employees before granting work permits (for example, during shutdown turnarounds). Using full-time instructors from the training center and standardized checklists creates an independent barrier. If a contractor's worker cannot demonstrate the correct use of a safety harness on the training ground, they do not receive a permit for work at height. Such a system clearly highlights the real qualification level of the engaged personnel and stimulates contractors to improve the quality of their internal training.

Scaling Experience with Limited Resources

The speaker shows by example that creating an effective system does not always require colossal budgets. Many elements can be implemented using decommissioned equipment, unclaimed items from warehouses, or temporarily assembling training structures from scaffolding right in the workshops. The main thing is methodological elaboration: understanding the target audience, proper group dynamics (so that one works while the rest do not stand idle), and algorithmization of actions.

What you will learn from this webinar:

• How to design a training ground to avoid equipment downtime and loss of learners' time?
• Why is integrating LOTO elements into all technical programs more effective than an isolated course?
• How to use checklists for justified refusal of admission to unqualified contractor personnel?
• What methodological mistakes turn expensive simulators into useless "hardware"?
• How to assemble a basic training complex from decommissioned equipment and scaffolding?