VR operator training simulator for power generation company

Customer

Large power generation company.

Problem

One of the key challenges faced by training centers in power generation companies is effective training of electrical personnel to operate power generation plants. This is crucial, as Electrical Safety Foundation International have reported numerous fatal incidents at power grid facilities across the world, resulting in the death of 126 people only in 2020. Additionally, competent equipment maintenance is essential to ensure its smooth operation.

Traditionally, the company’s employees had to upgrade their skills through hands-on training during live production processes. They either had to wait for a planned shutdown of a unit for repairs or work in short intervals within controlled access areas. Educational process was complicated and exposed workers to danger. 

Solution

We have developed a VR simulator designed to train operational and maintenance personnel working with 10kV switchgear. The simulator is built upon the Linux operating system. It includes a training application, a module for server administration and management.

How it works

Digital locations

We created fully replicated virtual versions of the real premises of the enterprise, where we “installed” virtual copies of the switchgear. To accomplish this, our team developed 500 virtual models of equipment and tools, including 400 interactive components, such as doors, switches, keys, carts, terminals, displays, sensors, insulators, bolts, personal protective equipment (PPE) and others.

Helmets and controllers

The simulator is installed through an executable file and deployed on the VR training server. The VR headset is then connected to the workstation. Employees can practice various switching procedures, maintenance and repair procedures within the simulator. They can virtually initiate the repair process for switchgear sections and bring them back into operation, as well as carry out major repairs.

Target scenarios

In collaboration with the customer, we introduced 3 sets of scenarios into the system, which fully correspond to real instructions, forms, regulations and switching programs. These scenarios guide electrical department employees to learn how to make rounds, perform switch operations and conduct repairs on sections.

It takes 6 hours to complete the program. The Rubius team has also developed a module to train how to use the simulator effectively. The module covers essential aspects, such as interacting with the equipment and navigating the virtual space. We ensure that employees can quickly adapt to the new technology.

Simulator modes

• Learning mode with instructions and tips: users can make mistakes and get comments and guidance throughout the training process.
• Training mode: hints are no longer provided, but users are still allowed to make mistakes.
• Exam mode: no hints, and each mistake made by the user reduces the final score.

Instructor role

The instructor controls the simulator using the teacher's virtual office. Instructors can assign scenarios to individual employees and track their statistics. Our solution automatically generates reports on training and testing results, and also saves video sessions for error analysis. Additionally, the instructor can join the session in real time and display it on the screen for group debriefing purposes.

Result

Advantages of using simulator:

• Minimizing the number of incidents and emergencies.
• Regular ongoing training to upskill employees without real equipment.
• Cheaper educational process and fast scaling of training materials.
• Quick onboarding for new employees.

The following results have been achieved:

• Continuous access to the simulator, allowing for skill and action development in both routine and emergency situations.
• Transparent statistics and testing the training level prior to working with actual equipment.
• Visual analysis of mistakes and increased employee engagement through interactive training formats.
• Regular training of new employees without the need for mentors.

At present, the project has been successfully implemented and is in commercial operation at the training center of the generation company. On average, several hundred specialists are planned to be trained using our simulator annually.