Virtual reality can be applied across all stages of plant engineering to provide benefits. In basic engineering, a 3D model acts as an integration and communication platform. It allows consideration of variants, visualization of simulations, and virtual inspections. In detail engineering, the 3D model enables integration of trades, ergonomic evaluations, and safety reviews. During commissioning, VR supports training and hardware-in-the-loop testing. Operational applications include training, AR process support, and teleservice. The technology provides benefits such as reduced errors, faster decision-making, optimized planning, and cost savings through decreased downtime and improved documentation.

1. Whitepaper
Virtual Reality in Plant Engineering
Applications, Benefits, Technologies
© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Dr.-Ing. Dipl.-Kfm. Christoph Runde
Virtual Dimension Center (VDC) Fellbach
Auberlenstr. 13
70736 Fellbach
www.vdc-fellbach.de
ϭ
Applications, Benefits, Technologies

2. Construction &
Retrofit
Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Environment: Plant engineering as a technical business segment aims at the
realization of technical plants. Plant engineering includes various technical
disciplines:
Process engineering
Energy / Electrical
engineering
Plant Engineering
Basics
2
engineering
Supply technology
Production technology
Plant planning
Mechanical engineering
Image: VRMMP

3. Construction &
Retrofit
Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Stages in development process [Source: Wikipedia http://de.wikipedia.org/wiki/Anlagenbau ]
1. Process development in the laboratory and technical center as well as an extrapolation to the
industrial scale ("scale-up")
2. Determination of the administrative, economic and technical conditions as well as the requirements
3. Feasibility study with technical and economic comparison of different concepts
4. Concept phase ([pre-planning]): selection of the final concept and initial estimations of the technical
system scope
5. Elaboration of the technically and economically most favourable concept and determination of all
expected costs
Basics
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expected costs
6. Approval planning to obtain the necessary permits
7. Detailed design and description of all necessary components and measures (execution planning or
detail engineering)
8. Request of the described (specified) components and services
9. Offer comparison and order
10. Construction of the plant
11. Commissioning of the system
12. Proof of the agreed services of the plant (material & energy turnover, quality, warranty data)
13. Handover of the system to the operator

4. Construction &
Retrofit
Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Assessment of costs vs. Cost incurrence
Problem intensified with project duration and complexity
Basics
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Example [Source: Munroe & Associates]

5. Construction &
Retrofit
Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Product lifecycle vs. Factory lifecycle
Different life cycles require
adaptability of the means of
production and integrative
planning
Basics
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Image:
Institut für industrielle Fertigung und Fabrikbetrieb,
Universität Stuttgart

6. Construction &
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Revamp & RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
VR in plant engineering: across all planning steps
Basic Engineering
Detail Engineering
sequence
Application across all planning steps
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3D model as an integration platform for
different trades
3D model as a communication platform for
different disciplines
Documentation & knowledge management
Reconstruction,
renaturation
Construction
Commissioning
Operation
Roughprocesssequence
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7. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
3D-model for integration and communication
Integration of geometry and kinematics
Integration of geometry and control
Integration with material flow and logistics
Integration of geometry and physics
simulation (structure, flow)
Integration of documentation
Image: Fraunhofer IPA
Daimler, Rastatt:
Robotics, supply,
material flow
Application across all planning steps
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Integration of documentation
Image: Fraunhofer
IFF
Image: ESI IC.IDO
Visualization of flow
conditions in plant
Interactive
documentation
on equipment (Example:
barrel extruder,
Extricom GmbH, Lauffen)

8. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Basic Engineering: VR application fields
3D model for authority planning
Presentation of plants and buildings in
the overall context
Use of 3D model for planning
General construction: terrain model,
roads, railways, existing buildings
Image: VRMMP
Complete overview on
plant
Basic Engineering
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roads, railways, existing buildings
Planning variants: longer retention of
variants in the planning process:
definition only when necessary
Virtual inspections, intuitive presentation
of the planning project for foreign
disciplines and non-specialists
Image: VRMMP
Image: Fraunhofer IFF
Highlighting of areas,
e.g. variants
Virtual walk-through

9. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Basic Engineering
Image: Fraunhofer IPA
Planning desk for 2D-3D-tasks
Basic Engineering
9
Image: VRMMP
Overall view with terrrain,
roads, gates, cooling water
reservoir

10. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Basic Engineering
Consideration of accidents, incidents
Representation of dispersion direction
pollutants in the course of time
With digital terrain model:
representation of flooded areas
Image: Hydro Image: Visenso
Pollutant dispersion at
drilling platform
Basic Engineering
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representation of flooded areas
Passing interpretation, diagnosis, search
for impurities, correction
Image: VRMMP
Image: VRMMPImage: VRMMP
Presentation of flood
in 3D-terrain model
Image left: fire on
electrical components
Image right: leakage
Image:
VirtualCitySystems
Simulation drop test (above real, below simulation)
Images: ESI
for Areva NP

11. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Basic Engineering
Consideration of accidents, incidents
Escape routes planning
Evaluation warning signs and escape
routes
Presentation of unclear paths in several
levels
Image: VRMMP
Escape routes via
upper floors
Basic Engineering
11
levels
Visibility in different weather conditions
In the event of an incident, blocked
paths (fire, pollutants)
Image: VRMMP
Image: Visenso
Visibility in the event of
snowfall: the next sign?
Blocked escape route
in the event of
leakage / fire

12. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Detail Engineering
Construction/ design support
Design support, geometry planning,
ensuring absence of collisions
Avoidance of multiple occupancy of
assembly space
Installation / removal inspections:
Image: VRMMP
Pipeline construction
Detail Engineering
12
Installation / removal inspections:
sequences, lifting devices, consideration of
limp materials (hoses, cables)
Geometric integration of different trades:
Virtual Mock-Up
Means of transport, conveyor technology
Variant planning
Image: Fraunhofer IPA
Image: ESI IC.IDO
Central pump station in
mine: possibility for side-
tilting loader to pass?
Review on production
plant, Gabler GmbH,
Ettlingen

13. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Detail Engineering
Simulation in 3D models
Process technology/ engineering
Structure and flow: ensuring functionality,
optimization
Automation technology: design automation
system
Image: VRMMP
Presentation process
simulation
Detail Engineering
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system
Image: Visenso
Image: VDC
Flow simulation
in turbine supply
Programmable logic
controler on 3D model
Simulation assembly process of a turbine, taking into account deformation by welding process
Image: ESI for Skoda Power

14. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Detail Engineering
Ergonomics and Usability
Strains, sight and gripping spaces
Usability, understandability
Noise/ vibration/ harshness, odour
Image: ESI IC.IDO
Interactive assembly
and accessibility
inspection with 3D
human model
Detail Engineering
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Noise/ vibration/ harshness, odour
Verification based on simulation models
Safety technology, accident prevention
Checking gripping areas
Checking separation systems, barriers,
sensors, processing (security concept)
Image: VRMMP
Image: Fraunhofer IPA
Virtual display
Safety cell

15. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Detail Engineering
Safety cell with separating
fences, light barriers, switches,
transfer boxes and an automation
system
Detail Engineering
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Image: Fraunhofer IPA
Image: Fraunhofer IPAImage: Fraunhofer IPA

16. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Construction Retrofit: VR-application fields
Return of the realization status in
planning documents
Laser scan + 360°-photography
Support project controlling
Change management
Construction
Retrofit
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Combination of laser scan and
geometry for transport
studies
Image: eSZett
Laser scan
Laser scan,
360°-photography
Image: Scantec 3D
Image: Scantec 3D

17. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Construction Retrofit: VR-application fields
Mixed data processing
Augmented Reality (AR)
Comparison reality digital 3D data:
Schedule newly constructed objects
in inventory
Image: Scantec 3D
Mixed data processing:
laser scan plus
3D-geometry
Construction
Retrofit
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in inventory
Review of digital documentation
Image: metaio
Image: Volkswagen
AR-planning
in existing system:
infrastructure
AR-planning
in existing system:
new series

18. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Construction Retrofit: VR-application fields
AR-planning
in existing system:
conveyor technology
Measuring function in AR
Construction
Retrofit
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Image: TU München
Image: Volkswagen
Image: Volkswagen

19. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Commissioning
Start-up support by partial simulation
Hardware-in-the-Loop: development and
evaluation of sensors, actuators, control
Procedures, emergency stop, startup,
shutdown
Image: Fraunhofer IPA
Overall diagram
system simulation
Commissioning
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Image: Fraunhofer IPA
Image: Fraunhofer IPA
Hardware-in-the-Loop:
control model, control
of real plant
Integration trades: robot
- robot cell – cell with
conveyor technology

20. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Commissioning
Training and qualification
Knowledge types which possibly have to be
managed in virtual environments:
1. Position knowledge
2. Structural knowledge
3. Behavioral knowledge
Image: VRMMP
Location and message of
a display
Commissioning
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3. Behavioral knowledge
4. Procedure knowledge
Possibilities of learning in virtual environments:
1. Spatial exploration
2. Conceptual learning
3. Learning motoric abilities
4. Procedural learning Image: Fraunhofer IPA
Image: VRMMP Functionality of a process
Operating a virtual control
using a Head-Up-Display

21. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Commissioning
Training and qualification
Learning levels: explain, accompany,
examine
Introduction of documentation
Introduction of simulators
Image: ESI IC.IDO
Explanation of
functionalities in front
of Powerwall
Commissioning
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Introduction of simulators
Scenario simulation
Visualization of the hidden Image: VRMMP
Image: VRMMP
Element which has to
be replaced,
designation
View in turbine

22. Construction
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Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Commissioning
Training and qualification:
Example high voltage transformer station
Mediation of all circuits via interactive
wiring diagram
Insulators and breakers can be opened
and closed in the circuit diagram
Image: 5DT
3D view of a
transformer station
Commissioning
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and closed in the circuit diagram
In the background, a high-voltage safety
program checks the correctness of all
operations
In the next step, operations are performed
via a simulated operator console
Image: 5DT
Image: 5DT
Circuit diagram with
spatial assignment
Simulated operator
console

23. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Commissioning
Commissioning
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Image: VRMMP
Plant training
simulator by the
Virtual Reality and
Multimedia Park
Turin:
definition of
scenarios, processing
of scenarios,
linked 2D and 3D
view

24. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Operation: VR-application fields
Training and qualification
AR process support
Teleservice AR-supported
Image: ESI IC.IDO
Tool change under
collision and slipping
conditions
Operation
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Image: Fraunhofer IPA
Image: ESI IC.IDO
Safety inspection of
the virtual plant at a
scale of 1: 1
Additional
information,
superimposed via AR-
display

25. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Revamp Revision: VR-application fields
• Return inventory and level of realization in
planning documents, variant consideration
• Support project controlling
• Change management
• Mixed data processing:
Laser scan- point cloudImage: Scantec 3D
Revamp Revision
25
• Mixed data processing:
scan plus new construction
• Accident/ incident consideration
• Removal, installation, disassembly and
accessibility inspections
• AR-supported scheduling of new geometries
in inventory
Image: ESI IC:IDO
Discussion in front of
Powerwall (visualized
laser scan geometry)
Laser scan- based
geometry generation
Image: Scantec 3D

26. Construction
Retrofit
Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Overview application areas
In the respective planning stages
Benefit
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27. Construction
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Revamp RevisionBasics Basic Engineering Detail Engineering Commissioning Operation Benefit
Potential benefits
Integrative 3D planning model
reduces voting errors
Transparency in planning, faster
decision-making
Inclusion of all disciplines
Cost reduction due to
Optimizing ergonomics and
usability
Merging reality and digital 3D
world
Fast, easy, understandable
documentation; use as a
Benefit
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Cost reduction due to
decreasing errors and
consequential costs
Shortening downtime
Optimized transport and escape
route planning
Assembly and disassembly
optimization
documentation; use as a
knowledge management platform
Training already during planning/
without occupancy of the plant/
harmless using scenario techniques
Image improvement through
modern technology

28. VDC members and partners regarding this topic
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29. Thank you very much for your interest!
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© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Virtual Dimension Center (VDC) Fellbach
Auberlenstraße 13
70736 Fellbach
www.vdc-fellbach.de
29