VIRTUAL TRAINING FOR SAFETY
Chenn Zhou
Director, Steel Manufacturing Simulation and
Visualization Consortium
Director, Center for Innovation through
Visualization and Simulation
Professor of Mechanical Engineering
Purdue University Calumet, Hammond, IN 46323
Where Ideas Become Reality
Missions
Innovation
Application
Education
Key Strengths
Integration of advanced technologies
Application driven approach for
problem solving
Partnerships
Background
Built on a long history of CFD
applications on various industries
including aluminum, glass (R&D 100
awards), power, refinery, steel, etc.
ABOUT CIVS
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3
3,700+
students used
CIVS for
learning
82 PUC
Faculty/Staff
800+ students
employed and
mentored &
44 awards of
best student
papers
20,500+ visitors & 200+ national and local news
$38 ++ million savings from 5 of over 130
projects
92 external
organizations
collaborated
Simulation
Visualization
High Performance Computing
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• A industry-led consortium: Steel Manufacturing Simulation and
Visualization Consortium (SMSVC).
• Result of the project is to establish the nation-wide consortium
and to develop a technology roadmap to benefit the American
steel industry.
• Project funded by National Institute of Standards and Technology
(NIST) Advanced Manufacturing Technology (AMTech) Planning
Grant, project period is June 2014 to May 2016.
Consortium Background
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SMSVC Advantages Will utilize CIVS proven applied research track records:
Integration of cutting edge simulation and visualization
technologies for superior visual outputs
Application driven approach for problem solving in diverse
areas
Close interactions with collaborators and responsive to
changes as needed
Will ensure:
Intuitive and innovative problem solving
Cost-effective options
Speedy solutions
Integration of production and training tools
Informative decisions to reduce cost and downtime
Where Ideas Become Reality
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Workplace & Process Safety:Example: Safety incident on a Melt Shop floor
Energy Efficiency:Example: Reheating Furnace – saved $30,000 annually at
ArcelorMittal
Operation Efficiency:Example: Expansion of production and shipping capability
is required at a steel plant
Reliability and Maintenance:Example: Crane – saved $8 million equipment avoidance
at USS
Workforce Development:Example: Virtual Blast Furnace for Training with excellent
feedback
Environment Impacts:Example: Sinter plant venture scrubber
Raw Materials Utilization:Example: Sinter Cooler – over $20 million capital cost
avoidance at ArcelorMittal
Smart Manufacturing:Example: Steel Plant Logistic Optimization
Focus Research Areas
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Workplace Safety Identified High Priority
• Reduce workplace fatalities to zero
• Achieve ability to recognize hazards
proactively
• Create and adopt MSV capabilities (tools,
modules) to educate workforce
• Achieve continuous safety learning processes
based on observations of what went wrong
during incidents
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Applications of MSV for Safety Training
• Virtual Reality enhances learning
experiences
• Improves understanding through pre-
test/post-test assessments
• Useful in teaching replicated and authentic
what-if scenarios
• Supports desired results for operational and
maintenance decisions
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Safety & Workforce Development Projects
Workshops I & II: Improving Steel Industry’s Image and Attracting/Retaining Workforce
Hot Rolling Simulation of Advanced High Strength Steels
Virtual Training to Improve Workplace Safety and Bridge the Skills Gap
Interactive Student-Steel Industry Programs and Tools
Early Intervention Maintenance for Improved Operational Efficiency
Virtual Simulation and Visualization Training: Safety, Operations, and
Maintenance
Board of Directors Proposed Project for 2016-2017: Develop Computerized In-House Training to Enhance Core Technical Training
Enhanced Training through CFD and Visualization to Operators for Greater
Understanding of the Processing
Virtual Training to Improve Workplace Safety, Operations and Maintenance
Simulation of Caster on Safety Awareness Improvement
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Discussions
What are the two main challenges that are obstacles to
good workplace safety? How could MSV help to address
these challenges?
What types of training scenarios are you most in need of
(i.e., that are insufficient today)?
What is the most important goal you’d like to achieve in
workplace safety, and the related unit operation or
equipment (i.e., reduce ‘blank’ in the blast furnace area)?
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VIRTUAL TRAINING/LEARNING
THROUGH SIMULATION AND VISUALIZATION
11
Better communication
Interactive, self-paced, &
more engaging experience
Situated, problem based,
work-based and real
scenarios
Authentic, immersive, and
emotional experience in a
virtual learning environment
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VIRTUAL TRAINING TECHNOLOGIES
Virtual Reality
PC, Projection, 3D TV, Oculus Rift
Augmented Reality
Phone, Tablet, Google Glass (HMD)
Interactive 3D Training
Safety, Maintenance, Controls
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CURRENT SAFETY TRAINING METHOD
o Plain text and image
Not comprehensive content
http://www.oshainfo.gatech.edu/techguides/falls-techguide.pdf
o Video and real demo
No possible consequence demonstration
https://www.youtube.com/watch?v=s5BZJ8K-N1w
o Online questionnaire
Still traditional classroom like
http://etraintoday.com/course-demo-time-restricted/?course_id=31
“Authentic learning is the interface between ‘true to life’ tasks, activities, and practices and their replicated
counterparts in virtual environments or classrooms, such that learners are forced to engage and react in a
similar manner as they would in a “real” situation…Truly authentic learning can be costly, dangerous…”
“Passive online learning designs constrain the experience as they often lack practical application and,
therefore, hinder the development of embodied coordination and cognition skills needed for deeper
understanding…”
-“Authentic, immersive, and emotional experience in virtual learning environments:
The fear of dying as an important learning experience in a simulation”
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CIVS METHODOLOGY
Validation & verification
3-D interactive multiple platforms including immersive
VR environment, AR, PC, mobile, or web versions
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CIVS EXAMPLES: SAFETY RELATED PROJECTS
1) Active Threat Emergency
Response Visualization
2) AMTEC (Automotive Technician
Training)
3) Blast Furnace – Interactive 3D
Virtual Training System
4) Crane Training 3D Simulator
5) Crane Safety Training using
Oculus Rift
6) Disaster Management Planning
7) Head Mounted Display Assisted
Lock Out Tag Out System
8) Hospital Emergency Response
9) Power Plant FGD Simulator
10) Steel Safety Virtual Scenarios –
Chain Storage Incident
11) Steel Safety Virtual Scenarios –
BOF Eruption
12) Steel Safety Simulators for Fall
Protection
13) Steel Safety Self-Paced Mastery
Training System
14) Vertical Edger Analysis
15) Virtual Boiler Augmented Reality
16) Virtual Construction
17) Wind Energy – Maintenance,
Troubleshooting and Safety
Simulator
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CIVS OTHER VIRTUAL TRAINING PROJECTS
1) Aircraft Radio Frequency
Distributions
2) Australia 100 (Math
Education)
3) AWAKE Virtual Learning
Modules
4) Brain Visualization
5) Canstruction Designer
6) Chemistry Molecular
Modeling
7) Crito Educational Game
8) Descartes Meditations
9) Digital Humanities –
Appealia
10) Disaster Management
Planning
11) Distributive Justice:
Education
12) Distributive Justice:
Nuclear
13) German Cultural Simulator
14) Ground Water Quality
15) Hospital Emergency
Response
16) Hydraulic Pump Training
17) Irish Dancing
18) Med Station for Training
19) Microbiology Lab Design
20) Mission Ocean
21) Nursing Sepsis
Evaluation Training
22) Planck Satellite
Visualization
23) Protein Structure
24) Reality University
25) Retirement Planning
26) Roller Coaster – Physics
27) Spine Structure
28) Steel Wheel
29) Ternary Phase Diagrams
30) Virtual Leadership
Simulator
31) Virtual Design HAST
32) Virtual French Poem
33) Virtual Nursery for
Planning
34) Virtual Steelmaking
35) Wind Energy – Wind
Farm Siting
36) Wind Energy – Wind
Turbine Template
37) Wind Energy – Wind
Turbine Wakes
38) Wind Energy – Virtual
Wind Turbine
39) Wind Energy – Control
and Monitoring
40) Wind Energy – Turbine
Design
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VIRTUAL WIND TURBINE SIMULATORS U.S. Dept. of Education FIPSE Project
Identified new technologies for virtual learning
Developed 7 simulators to improve student learning
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WIND ENERGY SIMULATOR ASSESSMENT
Six universities and community
colleges implemented simulators
in courses
Increased student content
knowledge
> 10% test score increase in
Engineering Courses
> 20% test score increase in
Technician Courses
Increased motivation to learn
about Wind Energy
www.windenergyeducation.org
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INTERACTIVE INCIDENT VISUALIZATION FOR
STEEL INDUSTRY SAFETY TRAINING
Objectives:
Improve safety training in the steel industry
Develop interactive 3D visualization based
on actual incidents
Outcomes:
Created interactive 3D scenario based on
real incidents in multiple platforms Chain Storage
BOF Eruption
Fall Protection
Allow trainees to experience consequences
of unsafe actions
“Unpack” the choices that lead to the incident
AIST Foundation Don B. Daily Memorial Fund Grant Recipient
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HEADS-UP ASSISTED
LOCK-OUT / TAG-OUT
Optical Head Mounted Display for
increasing safety during lock-out and
tag-out procedures
Remotely access to online directory of
all procedures
Visual walkthroughs
Timestamped record of procedure
completion
Student wearing the Epson Moverio device.
View through HMD of lock-out procedure.
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VIRTUAL “AIMS” SIMULATOR FOR
MAINTENANCE AND TROUBLESHOOTING
Goals: To provide an innovative solution for optimizing
learning effectiveness.
To integrate the interactive virtual training
simulator into the AMTEC curriculum for two-year
technical programs to fill the technical skills gap.
Expected Outcomes A web-based 3D Virtual Simulator, based on the
physical AMTEC Instructional Manufacturing
Simulator, with fault-based scenarios that
provides students with unlimited opportunities for
practice and supports instructional delivery of the
AMTEC curriculum for improved educational
outcomes.
Where Ideas Become Reality
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VIRTUAL BLAST FURNACE
Multiple versions of training package
– PC, Web, Mobile
– 3D TV
– 3D Immersive Virtual Reality (VR)
– Augmented Reality (AR)
Taught in industrial training and short
courses world wide
Used for problem solving for design,
troubleshooting and optimization with
multimillion savings and cost
avoidance
Where Ideas Become Reality
"excellent training tool; great problem-solving capabilities."
"This interactive model helped me visualize the material flowing through the
process. It was very helpful in understanding the flow"
VIRTUAL BLAST FURNACE FOR TRAINING
30
U.S. Steel Blast Furnace Ironmaking Academy
Total 20 ParticipantsStrongly
Agree
Agree Neutral Disagree Strongly
Disagree
The VBF simulator was beneficial as a
visual learning aid in this training
course.
95% 5% 0% 0% 0%
The VBF simulator enables me to
better visualize the blast furnace and
its equipment in a way that is difficult
for me to do with presentation slides or
text alone.
85% 15% 0% 0% 0%
Training courses on other process
(i.e., cokemaking, steelmaking, etc.)
should develop similar simulations in
the futures as a learning aid.
80% 20% 0% 0% 0%
Where Ideas Become Reality
Issues:
Limitation in existing training
capabilities
Difficult to prepare personnel for
failure scenarios
Outcomes:
3D virtual model with real geometry,
operating conditions and CFD
Simulation Data
3D Interactive Training Software
package in VR, AR, PC, Mobile
FGD MODEL FOR SAFETY AND EMERGENCY
TRAINING
3D views of Schahfer Generating Station
NIPSCO Schahfer Station
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Issues: Unexpected Failure
Production Delay
Safety Concerns
Outcomes: Identified critical areas by
conducting structural analysis
Predicted remaining equipment
life by conducting fatigue
analysis
3D Interactive Training Software
package in VR, AR, PC, Mobile
VIRTUAL VERTICAL EDGER
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Issues:
Training time for operators is
limited
Traditional 2D, non-scaled
presentation materials provide
limited information during training
Outcomes:
3D virtual boiler with real
geometry, conditions and CFD
data
Multiple scenarios for different
operating conditions 3D Interactive Training Software
package in VR, AR, PC, Mobile
VIRTUAL POWER PLANT FOR TRAINING
NIPSCO Scahafer Station
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3-D FLOOD SIMULATION AND
VISUALIZATION FOR
LEARNING
NSF Funded Project (DUE
1245883)
Improved learning in Civil
Engineering Hydrology and
Hydraulics courses
Transformed teaching practices in
water resources engineering
Implemented at 4 colleges
Upcoming workshop to implement at
10 additional colleges
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ACTIVE THREAT/SHOOTER FOR EMERGENCY
PLANNING
Objectives: To help provide a breakdown of
procedures to be followed during an
active threat situation
Provide accompanying visualization
for live-action scenarios
Outcome: Developed 7 clips outlining key
points of an active threat situation
Used by Franciscan St. Margaret
Health for Emergency training
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Virtual Education/Training Publications1) Do, P., Moreland, J. (in press). Facilitating Role of 3D Multimodal Visualization and Learning
Rehearsal in Memory Recall. Psychological Reports, 114(2).
2) Moreland, J., Dekker, G., Okosun, A., Wang, X., Zhou, C. (accepted). "Virtual Training for Wind
Turbine Technicians" AWEA Wind Power Conference, Las Vegas, NV. May 5-8, 2014.
3) Zhao, Y., Capo, J., Best, M., Wang, T., Phillips, L., Wang, J., Fu, D., Moreland, J., Zhou, C.
(submitted). "Development of a Virtual Blast Furnace Training System". AISTech - Iron and Steel
Technology Conference. Indianapolis, IN. May 5-8, 2014.
4) Zhou, C. (2013). "Simulation and Mixed Reality for Wind Turbine Education". BIT 3rd New Energy
Forum. Xi'an Qujiang, China. September 26-28, 2013.
5) Dekker, J., Zhang, Q., Moreland, J., Zhou, C. (2013). "MARWind: Mobile Augmented Reality Wind
Farm Visualization" in Proceedings of WorldComp 2013 International Conference on Modeling,
Simulation and Visualization Methods. Las Vegas, NV.
6) Do, P. T., Moreland, J. R., Delgado, C., Wilson, K., Wang, X., Zhou, C., & Ice, P. (2013). Effects of 3D
virtual simulators in the introductory wind energy course: a tool for teaching engineering
concepts. Innovative Teaching, 2(1).
7) Moreland, J., Wang, J., Liu, Y., Li, F., Shen, L., Wu, B., Zhou, C. (2013). "Integration of Augmented
Reality with Computational Fluid Dynamics for Power Plant Training" in Proceedings of WorldComp
2013 International Conference on Modeling, Simulation and Visualization Methods. Las Vegas, NV.
8) Moreland, J., Wang, X., Do, P., Zhou, C. (2013). "Mixed Reality Simulators for Wind Energy
Education". American Wind Energy Assocation WindPower Conference. Chicago, IL.
9) Moreland, J., Dubec, S., Okosun, T., Wang, X., Zhou, C. (2013) “A 3D Wind Turbine Simulator for
Aerodynamics Education”. ASME 2013 International Mechanical Engineering Congress. San Diego,
CA, USA. 2013.
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Virtual Education/Training Publications10) Guo, S., Moreland, J., Viswanathan, C., Zhou, C. (2012). "Virtual Reality System for Solute Transport
in Groundwater", 2012 Annual ASEE IL/IN Section Conference, Valparaiso, IN, USA.
11) Moreland, J., Okosun, T., Wang, C., Wang, X., Zhou, C. (2012). "Development and Pilot
Implementation of a Virtual Wind Turbine Simulator" AWEA Wind Power Conference, Atlanta, GA.
12) van der Veen, J., McGee, R., Moreland, J. (2012). "The Planck Visualization Project: Immersive and
Interactive Software for Astronomy and Cosmology Education". IDEAL 2012 (International Dynamic,
Explorative, and Active Learning Conference). Bayburt, Turke
13) Dekker J., G. A., Moreland, J., and van der Veen, J. (2011). "Developing the Planck Mission
Simulation as a Multi-Platform Immersive Application", Proceedings of the ASME 2011 World
Conference on Innovative Virtual Reality, WINVR2011, Milan, Italy.
14) Do, P.T., Korchek, D.P., Moreland, J.R., & Lin, H.S. (2011). "Innovative applications of 3D multimodal
visualizations in engineering and technology education as a function of memory rehearsal". American
Society for Engineering Education (ASEE): Albany, NY.
15) Viswanathan, C., Moreland, J., Guo, S., and Zhou, C. (2011). "Usefulness of Virtual 3D Modeling to
Visualize the Effect of Uncertain Data In Groundwater Solute Transport". Proceedings of the ASME
2011 World Conference on Innovative Virtual Reality, WI
16) Do, P. T., Korchek, D. P., & Moreland, J. R. (2011). "Educational Application of 3D Interactive,
Dynamic Multimodal Visualizations in Virtual Learning Environments". Conference for Industry and
Education Collaboration. San Antonio, TX, USA. February 2-4, 2011.
17) Do, P., Moreland, J., and Korchek, D., (2010). “The Influence of Multimodal 3D Visualizations on
Learning Acquisition”. 6th International Symposium on Visual Computing, Las Vegas, NV, United
States, Vol. part III , pp. 484-493.