Learning from history: Why PtX technology demands a new training paradigm

The transition to Power-to-X (PtX) technologies represents a significant shift in global energy systems. As industries rush to implement and integrate solutions like green methanol and green ammonia, the urgency to establish robust safety and competency training has never been greater.

Even in industries with ambition to scale rapidly such as Power-to-X, the necessity of taking the time, care and due diligence to plan for safety and training cannot be understated.

History warns us of the risks of underestimating safety in new technological frontiers. We recently sat down with Per Larsen, Head of Innovation and Product Management at Maersk Training, to learn about the history of Maersk Training, the defining role the 1977 Maersk blowout incident had in its creation, and how all this history lead to exploring the future standards of PtX safety training with Topsoe.

A Defining Moment in Safety Training Evolution

Maersk Training was founded in direct response to the 1977 gas blowout, an incident that occurred when a Maersk Drilling rig struck a gas pocket, triggering a blowout that set fire to the rig and put the lives of its crew at serious risk.

“This could have been our Deepwater Horizon moment”, explains Larsen, “the only difference was that we were extremely lucky.” While all personnel on board had received the necessary level of training for the time “when things became critical, the emergency organization fell apart, and everyone did exactly what they were not supposed to do”.

This incident exposed a critical gap present for training at the time: a certain level of training will prepare you with all the necessary information before an incident, but it takes another level entirely to follow procedure during one. While events like these were not unusual for the industry at the time, it was the catalyst for a subsequent chain of events that would change the industry for good.

After the 1977 incident, Maersk Training emerged and a revolution in safety training began —one that prioritized realism, behavioral competencies, and a shift in organizational culture. Founded in the company’s priority of “constant care”, Maersk Training was established to instill skills beyond procedural checklists, focusing instead on mindset, decision-making under pressure, and practical emergency response.

The unique challenges of Power-to-X

Nearly 50 years have passed since the 1977 incident, and the vast learnings and experience Maersk Training has amassed over this time are essential foundations on which PtX can build a sustainable and safe future.

Although, PtX is not without its unique challenges. While the presence of high-pressure systems, volatile chemicals, and new applications of existing technologies is not dissimilar from other sectors such as offshore drilling, wind and solar – PtX is facing an expedited timeline to meet industry’s decarbonization ambitions. This transition must happen within a small window of time to meet Net Zero goals, leaving no time for reactive learning from accidents.

Without established regulatory standards or precedent, the PtX industry must take the lead in developing safety and competency frameworks. The question facing many companies today is whether they should invest in new comprehensive training programs or rely on the pre-existing standards from other industries. The lesson from Maersk’s history is clear: waiting for regulations or relying on potentially outdated training methodologies is not an option.

Learning from the Past to Shape the Future

The Maersk experience underscores three key takeaways that PtX must integrate into its safety strategy:

1. Training Must Be Realistic and Situational

Employees in PtX environments must train under conditions that closely mimic real-world scenarios. Simulation-based learning, VR-enhanced safety drills, and crisis management exercises should be central components of PtX training.

2. Competency along with certification

Compliance checkboxes do not equate to real-world readiness. Training must focus on behavioral competencies, decision-making, and emergency response, ensuring workers can act effectively when faced with unforeseen challenges.

For example, in 1977, the issues identified in the investigation were not in a lack of qualifications, it was in a lack of competencies on deck. As Larsen explained: “When you look at what happened on the rig, it was clear that there were some competencies lacking related to how realistic previous training was, and if it actually mirrored what happens when things go wrong in real life.”

3. Culture Determines Safety Outcomes

Organizations must embed safety deeply into their culture. In high-risk industries, cutting corners for efficiency can become normalized over time. Training must not only reinforce safety procedures but also instill a mindset that prioritizes risk awareness over operational speed.

To create an effective culture around safety, identifying even the smallest risky behaviors is important, because when left unchecked they can accumulate into a risk prone culture. As Larsen explains it through the framing of offshore drilling: “you can measure and track a lot of things in this industry, but sometimes people are still tempted to cut corners or bypass safety rules in order to keep productivity up. If you continue to do that over time and nothing happens, you start to normalize risky behavior and keep on repeating it, to the detriment of everyone else.”

Strengthening PtX Safety Through Partnership

Exploring a potential partnership between Topsoe and Maersk Training would be a strategic move to set new industry benchmarks in PtX safety.

"We bring more than 100 years of history in Maersk and nearly 50 years of experience in training," says Larsen, "but we also recognize where we benefit from partnerships—where additional expertise makes us stronger."

Through this collaboration, Topsoe and Maersk Training would aim to develop industry-leading safety and competency training that goes beyond compliance. "This is not just about ticking boxes; it's about making sure the people on the front line—the ones making things happen—are equipped with the right skills and mindset," Larsen emphasized. By working together, Topsoe and Maersk Training are defining safety standards that will shape the PtX industry for years to come.

The Road Ahead: PtX Needs a New Training Standard

“What has happened over the past 50 years is a shift of mindset.”

The challenges of PtX safety are unique, requiring an industry-led effort to create new competency benchmarks. By integrating insights from Maersk’s safety evolution, the PtX sector can proactively shape its training standards before regulatory bodies catch up. Partnerships like those between Topsoe and Maersk Training are critical in building the training frameworks that will define the industry’s future.

History has shown us what happens when training falls short. As PtX technologies scale, the industry has the chance—and the responsibility—to ensure safety is not left to luck.