The real-world benefits of virtual reality training

Virtual reality training is changing the way risk and skill are managed in engineering industries. It’s time more utilities took advantage of the technology, says Stephen Chadwick.

Companies in the global utilities industry are under intense pressure from all directions.

The oil and gas segment in particular has significant challenges. Many upgrade, refurbishment and maintenance projects involve hundreds of workers who must be thoroughly trained – especially in safety-related operations such as handling fires, toxic chemicals, high-pressure leaks and other emergency incidents. Scheduling requires precise choreography to ensure each step occurs on time and in proper sequence.

A growing number of companies in the pipeline and gas industry are addressing these challenges through the use of 3D virtual planning, simulation and visualisation technologies. Such systems allow people to plan and schedule operational procedures, train workers and meet health and safety requirements by interacting with a computer-simulated 3D environment, including cranes, plant assets and workers to determine the best process to minimise costly project delays and mitigate risk.

By studying procedures in this virtual world, engineers, planners, safety experts and workers can identify problems, explore options and determine the best remedy without disrupting actual plant operations. With lifelike 3D models, simulations and visualisations, planners can test their project plans virtually, and workers can see precisely what they need to do before they attempt it on the job. In this manner, optimal procedures and scheduling of operations can be worked out before projects are started in the plant or along the pipeline and workers can be safely trained off-site.

Traditional ways of planning rely on the experience of workers and subcontractors to execute the required maintenance tasks, supported with 2D information. But 2D drawings and historical information are often inaccurate and outdated, leading to miscommunications between the various project teams during the actual execution. This results in expensive delays to the project, unsafe working conditions and costly project rework.

3D simulation-based systems for planning scheduled maintenance or new operational procedures provide an effective way for engineers to develop precise and detailed plans to execute work right-first-time by studying various scenarios and performing “what-if” evaluations well before tasks are attempted.

In advanced systems, scheduling software is often coupled with process planning simulations in an integrated solution that optimises schedules for day-to-day plant operations as well as periodic maintenance tasks. By iterating with process planning in evaluating various what-if scenarios, the scheduling solution analyses alternative sequences and arrives at an optimised master schedule. This output is invaluable to project managers and others in determining budgets, manpower requirements, critical timelines and operating efficiencies.

Virtual reality (VR) training systems create a lifelike, immersive environment that adds another dynamic dimension to 3D simulations. VR enables users to interact with computer-simulated equipment and surroundings with lifelike realism.

Most of these applications are used in worker training, where some of the most advanced systems use 360-degree wrap-around theatres with photo-realistic imagery viewed with stereoscopic glasses. Multiple speakers generate high-fidelity sound effects to familiarise workers with the harsh and sometimes subtle sounds found on job sites, which might include a variety power plants, transmission hubs or treatment works.

Head-mounted goggles track head and eye movements, allowing the system to recognise where users are focusing their attention in the overall scene. In this way, workers can be trained off-site using VR without disrupting normal work routines or exposing them to the real hazards.

In any of these systems, different maintenance and operations scenarios can be performed without workers being on the actual site. Another benefit is that workers can familiarise themselves with sites – potentially before they exist in the real world.

Workers can learn specific operations and maintenance procedures so they are immediately productive. A report issued at the end of virtual reality training indicates which tasks were successfully performed and which mistakes were made, so employees can be coached on individual skills while the company is able to create regulatory documentation.

Companies in the energy industry are leveraging simulation technology to ensure workers are well prepared with the skills and knowledge necessary to work safely in an unforgiving environment.

These organisations are increasing productivity and lowering costs by better planning operations and maintenance procedures, maximising workflow and utilisation of resources with detailed and co-ordinated scheduling, and making plants safer and more efficient with comprehensive simulation-based training.

The business value of these applications is immense in reducing the costs of non-productive time measured in hundreds of millions of pounds annually and avoiding the billions lost every year in this complex industry due to operating inefficiencies.