VIRTUAL TRAINING FOR SAFETY - steelconsortium.org TRAINING FOR SAFETY Chenn Zhou Director, Steel Manufacturing Simulation and Visualization Consortium ... Virtual Blast Furnace for

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


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


• 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


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


6

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


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


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


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


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)?


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


VIRTUAL TRAINING TECHNOLOGIES

Virtual Reality

PC, Projection, 3D TV, Oculus Rift

Augmented Reality

Phone, Tablet, Google Glass (HMD)

Interactive 3D Training

Safety, Maintenance, Controls


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”

http://www.oshainfo.gatech.edu/techguides/falls-techguide.pdf

https://www.youtube.com/watch?v=s5BZJ8K-N1w

http://etraintoday.com/course-demo-time-restricted/?course_id=31


CIVS METHODOLOGY

Validation & verification

3-D interactive multiple platforms including immersive

VR environment, AR, PC, mobile, or web versions


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


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


Turbine Template


Turbine Wakes

38) Wind Energy – Virtual

Wind Turbine

39) Wind Energy – Control

and Monitoring

40) Wind Energy – Turbine

Design


VIRTUAL WIND TURBINE SIMULATORS U.S. Dept. of Education FIPSE Project

Identified new technologies for virtual learning

Developed 7 simulators to improve student learning


SAFETY & MAINTENANCE TRAINING VIDEO


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


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


INTERACTIVE SAFETY TRAINING

Chain Storage / Crane Operation Demo



Self-Paced Safety Training Demo



Fall Protection Training Demo



Oculus Rift Crane Demo


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.


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.


VIRTUAL AIMS SIMULATOR DEMO VIDEO

27


28

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


VIRTUAL BLAST FURNACE DEMO VIDEO

29


"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%


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


32

VIRTUAL FGD DEMO VIDEO


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


VIRTUAL VERTICAL EDGER


VIRTUAL VERTICAL EDGER VIDEO


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


VIRTUAL POWER PLANT FOR TRAINING

NIPSCO Scahafer Station


AUGMENTED REALITY POWER PLANT VIDEO


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


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


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.


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.

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VIRTUAL TRAINING FOR SAFETY - steelconsortium.org TRAINING FOR SAFETY Chenn Zhou Director, Steel Manufacturing Simulation and Visualization Consortium ... Virtual Blast Furnace for