How VR Training in Refineries Delivers Safety and Operational Excellence?

Virtual reality training has emerged as a significant tool in the oil and gas industry, revolutionizing the way employees are trained and enhancing operational efficiency. As outlined in Technavio’s report, the oil and gas industry are driven by a need for advanced technologies. With immersive and realistic simulations, VR training in refineries enables workers to practice critical tasks and emergency procedures in a safe and controlled environment, reducing the risk of accidents and improving overall performance. Global Data’s research reveals that major players in the oil and gas sector, including BP, Chevron, Shell, and Saudi Aramco, use virtual reality in all aspects of their operations, including upstream, midstream, and downstream.

 1.) Enhanced Safety

VR training enables employees to practice risky activities and emergency procedures in a well-designed VR training application that may accurately simulate a genuine working environment, lowering the likelihood of accidents and injuries. For instance, oil rig operators can simulate firefighting scenarios, enabling them to gain practical experience in handling emergencies without exposing them to actual danger.

 2.) Savings

With VR, there is no need to use and deplete costly equipment, or to send busy, high-paid instructors or skilled staff to remote locations for instruction. Companies can significantly reduce their travel, accommodation, and equipment maintenance expenses. BP is one example of a company that used VR training to increase employee learning effectiveness while reducing training expenses by 30%.

 3.) Improved Knowledge Retention

VR training enhances knowledge retention through its immersive nature. Trainees are actively engaged in the virtual environment, leading to better memory retention and improved learning outcomes. A study by Stanford University found that VR learners were four times more focused and had a higher retention rate compared to traditional classroom training.

 4.) Remote Training Opportunities

VR training enables remote and decentralized learning, allowing employees in different locations to access the same training programs and scenarios. This is particularly beneficial for multinational oil and gas companies with operations in diverse geographical locations.

 5.) Realistic Simulations

VR technology services provide highly realistic simulations that closely resemble real-world oil and gas operations. Trainees can interact with virtual machinery, equipment, and complex systems, enabling them to gain practical skills and experience. Chevron, for instance, implemented VR training for pipeline inspections, allowing inspectors to identify potential issues and practice inspection techniques without interrupting actual operations.

VR Training to Maintain High Safety & Performance Standards

Typical VR Training in Refineries

Employee orientation often kicks off refinery training, which covers crucial safety protocols. Additionally, they educate staff members about permit-to-work laws, lockout tagout procedures, restricted spaces, working at heights, electrical safety, scaffolding, vehicle safety, lifting techniques, and other topics. Training is always given in a classroom setting utilizing slide presentations, which incorporate pictures and videos but are, monotonous and uninteresting.

Here, VR training sessions can be helpful since they give participants hands-on experience through interactive modules and realistic simulations, enhancing safety procedures. For example, refinery workers may participate in virtual scenarios where they learn how to respond to a chemical leak or perform equipment maintenance. They can practice identifying potential hazards, donning personal protective equipment (PPE), and executing proper emergency protocols. Through realistic visuals and haptic feedback, trainees can manipulate virtual valves, inspect equipment, and troubleshoot issues in a virtual replica of the refinery. These simulations allow workers to gain practical skills, improve decision-making in critical situations, and develop a deep understanding of refinery operations while minimizing the risks associated with hands-on training.

Operations & Maintenance Training

VR simulations enable trainees to interact with virtual replicas of complex equipment, such as pumps, compressors, and control systems. They can explore the equipment’s functionalities, understand its components, and learn how to operate and maintain it effectively. This hands-on experience in VR training provides a platform for O&M personnel to practice various procedures, including routine maintenance tasks, troubleshooting common issues, and executing maintenance workflows. Trainees can simulate scenarios that mimic real-world challenges, allowing them to develop problem-solving skills, identify faults, and apply correct maintenance procedures.

For example, to understand how a mechanical seal is built or put together, a worker does not need to struggle with intricate 2-D general arrangement drawings or section drawings. The seal can be guided through assembly and disassembly using a VR module to ensure its proper installation on a pump shaft. It can be simulated and even gamified to make the whole process more interesting to ensure no mistakes are made when complex machinery is being serviced or repaired during outages. Not only is it done correctly, but it also avoids rework, which is a major cause of safety issues and cost overruns.

Disaster Management Training

VR training has proven to be a game-changer in disaster management training within the oil and gas industry, by providing virtual training in severely toxic environments, simulating evacuations, and emergency response. VR simulations allow workers to experience critical situations, such as blowouts or pipeline leaks, in a controlled virtual environment, enabling them to practice decision-making, communication, and emergency protocols. By repeatedly engaging in these virtual scenarios, personnel develop the skills, confidence, and muscle memory needed to respond effectively during actual disasters, minimizing the impact on human lives, the environment, and company assets.

Human Factors Training

The impact and efficacy of VR training must be personally experienced by Chief Operating Officers, Plant Managers, and Operations Managers. As a result, they develop the strategic vision needed to create teams, assign resources, and offer leadership support for implementation projects. Refinery operations often involve teamwork and coordination among different personnel. VR training can simulate collaborative scenarios, such as coordinating shutdowns, emergency responses, or communication protocols, to improve teamwork and decision-making skills. By practicing these scenarios virtually, workers can enhance their understanding of human factors, reduce errors, and improve overall operational excellence.

To Sum Up

The oil and gas industry has embraced VR training as a powerful tool, empowering workers with practical skills, standardized training, and a heightened focus on safety and operational excellence. Real-life examples illustrate the tangible benefits of VR training. Shell, for instance, creates simulations for deepwater safety instruction using VR development services. ExxonMobil makes use of immersive technologies when training workers, primarily engineers and plant operators, for emergency shutdowns, abnormal operations, and disaster response. As leading VR development company with more than a decade of experience, we developed cutting-edge, user-friendly, and affordable VR training in refineries for the oil and gas sector.

Contact us today to discuss your unique business needs and let us craft a tailored solution that takes your organization to new heights!