A New Philosophy: From Compliance to a Preventive Culture

The most significant transformation lies in the shift from a compliance-based to a prevention-oriented safety culture. The goal is to build a system in which every employee — from operators to top management — is motivated and equipped to identify potential risks in advance.
In September 2025, a new national safety standard came into force, based on ISO 45001 principles but extending them significantly. It mandates that hazardous production facilities implement predictive analytics systems and regularly conduct stress tests using digital twins to simulate emergency scenarios.
For example, all nuclear power plants in Russia now perform quarterly simulations of complex combined threat scenarios — including simultaneous cyber and physical attacks — allowing them to identify vulnerabilities and strengthen protective measures before incidents occur.

Technology on Guard: AI, Drones, and Digital Twins

Unmanned Monitoring.
The use of drones for inspecting hard-to-reach and hazardous areas has become widespread. At a refinery in Ufa, UAVs equipped with LiDARs and gas analyzers survey hundreds of kilometers of pipelines and flare stacks daily. AI-driven computer vision algorithms detect early signs of corrosion, seal leaks, or explosive gas accumulation. As a result, the number of personnel required to work in dangerous zones was reduced by 40%, while inspection frequency increased by 25%.
Predictive Analytics.
Artificial intelligence has become a central tool for accident prevention. In the Kuzbass coal mines, a slope stability monitoring system combines data from ground-penetrating radars, seismic sensors, and drones. The AI model predicts potential landslides 48–72 hours in advance, enabling timely evacuation of people and machinery. In September, the system successfully prevented an incident at the Kedrovsky open-pit mine, forecasting rock displacement with 5-meter accuracy.
Digital Twins for HSE (Health, Safety, Environment).
Digital replicas of industrial sites are now used not only for process optimization but also for safety training and risk assessment. Virtual simulators enable workers to practice responses to fires, oil spills, or chemical leaks without endangering lives. At ZapSibNeftekhim, a digital twin was used to model 15 different emergency scenarios, leading to a 30% improvement in the efficiency of the emergency notification and evacuation system.

Cybersecurity for Critical Infrastructure

Cyber threats have moved from the virtual domain into the physical. A successful attack on an industrial control system can cause real-world destruction and casualties. In September, under the initiative of the Russian Security Council, large-scale exercises were held to simulate coordinated cyberattacks on energy and chemical facilities.
Following the drills, a new cybersecurity standard was introduced, requiring the use of sandbox environments for testing all incoming software, as well as physical air gaps between process control networks (ICS/SCADA) and corporate IT systems at critical facilities.

The Human Factor: New Professions and Retraining

The technological shift has created demand for entirely new professions in the safety domain:

• City Farmer – a specialist responsible for cultivating edible plants on industrial sites to biologically monitor air and soil quality.
• Cyber-Physical Security Engineer – an expert who understands both IT threats and physical production processes.
• Predictive Risk Analyst – a professional working with AI-based forecasting systems and translating data insights into actionable safety measures.

To support this transition, a Corporate Academy pilot project was launched in September by Rostekhnadzor in partnership with leading technical universities, aimed at training a new generation of safety specialists.

Conclusion

Industrial safety in Russia is undergoing a renaissance, evolving from a restrictive function into a data-driven, predictive risk management system. It is no longer seen merely as regulatory oversight but as a strategic asset — directly influencing a company’s reputation, financial resilience, and competitiveness.
Investments in safety are now recognized as investments in sustainable development and technological leadership, a paradigm clearly demonstrated by the events of September 2025.