Safe and correct handling of failures in the cooling systems of melting furnaces is critical to protecting life, health, and expensive industrial equipment. At the same time, incorrect actions or unnecessary shutdowns can have significant economic consequences. In this project, NORCE has evaluated VR Safe, a virtual training environment designed to prepare melting furnace operators to handle critical incidents.
VR Safe is a VR-based training solution that simulates realistic scenarios related to failures and leakages in the cooling systems surrounding melting furnaces. The system was developed by Agder XR Productions in collaboration with industrial partners and recreates both the furnace facilities and the cooling system in a three-dimensional environment, presented through virtual reality head-mounted displays (HMDs). The virtual model is, among other things, based on “Furnace 5” at Elkem Bremanger.
Purpose and Research Questions
The purpose of the project was to investigate how melting furnace operators experience training in virtual reality, with particular emphasis on:
- Usability and technical quality
- Engagement and immersion
- Perceived learning outcomes and relevance to everyday work
The project is grounded in the recognition that many critical incidents occur infrequently but may have severe consequences, making them difficult to train for in real industrial environments.
Method
The evaluation is based on experiential data collected from operators who completed training using VR Safe. The data include qualitative assessments of user experiences, as well as reflections on learning, situational awareness, and the transfer of skills and knowledge to real-world work situations.
Main Findings
The results show that VR-based training is experienced as both engaging and highly relevant. Operators particularly highlighted:
- Improved understanding of the relationship between measurements in the control room and actual events in the furnace facilities
- The possibility to practice hazardous situations without risk to personnel or equipment
- Better conditions for developing judgment and decision-making skills in complex and time-critical situations
VR training was regarded as a valuable supplement to existing training methods, especially for practicing rare but critical events.
Impact and Significance
The project demonstrates that VR-based training solutions can contribute to more robust and experience-based training in the process industry. The results provide a knowledge base for further development and implementation of VR as a tool for safety, competence development, and risk-reducing training in industrial contexts.
