Virtual Reality Applied to Training and Process Safety: A Semi-Industrial Boiler Case Study

The short-term time given to learn a particular task associated with the demands for higher levels of production to increase profits are potential reasons for the generation of accidents. Seeking to overcome this situation in training a large number of operators in a similar environment in which they will work, a 3D (three-dimensional) SCADA, integrating phenomenological simulation developed in Matlab, and Virtual Reality (VR), using Plant Design Management System© (PDMS), were developed in this work. Additionally, the developed 3D plant model based tool allows different safety tasks, such as the optimum location of fire extinguishers, fire hoses and escape routes, among others. As a case-study, a semi-industrial boiler, located in Escola de Química, Universidade Federal do Rio de Janeiro (Federal University of Rio de Janeiro), was chosen. The interaction between the user and 3D model was addressed by developing a process data interpreter, so that the model may been modified on the basis of actions taken by the operator. As the developed tool improves the operator’s understanding of the process, it may minimize rework, accidents and damage. Additionally, this methodology may be replicated in other industrial plants.