Main and Control Screens, VR Headset
The development team for this project aimed to simulate the environment and its objects as realistically as possible, ensuring an authentic and natural user experience. We meticulously refined many details, including elements that might initially seem secondary. This included the heating system, the proper placement of emergency signaling components, carefully designed lighting and shadows, and realistic reflections on imperfect surfaces. Such attention to detail transforms an abstract 3D model into a lifelike object — one that users want to explore and interact with. This level of realism enhances immersion in the virtual environment, making the experience truly memorable.
High-visual-fidelity digital twins engage viewers and allow them to quickly grasp the essence of how equipment or processes function. The Gaidamaka.pro team believes that such models are valuable not only for clear demonstrations but also for practicing and reinforcing essential skills — something backed by research from the analytical firm Gartner. When combined with the right mathematical modeling of displayed processes, virtual simulations evolve into full-fledged debugging tools.
Furthermore, we see the potential to adapt these systems for affordable standalone VR headsets, significantly reducing costs for implementing such technologies.
High-visual-fidelity digital twins engage viewers and allow them to quickly grasp the essence of how equipment or processes function. The Gaidamaka.pro team believes that such models are valuable not only for clear demonstrations but also for practicing and reinforcing essential skills — something backed by research from the analytical firm Gartner. When combined with the right mathematical modeling of displayed processes, virtual simulations evolve into full-fledged debugging tools.
Furthermore, we see the potential to adapt these systems for affordable standalone VR headsets, significantly reducing costs for implementing such technologies.
Project outcomes
In our case, a booth assistant carefully guided unprepared viewers through all the operational algorithms of the station. They helped users move from one location to another, demonstrating what would happen if a specific system parameter changed and how the entire system would respond. With the active support of the assistant, participants did not feel disconnected from reality and remained highly engaged with the simulation. We believe that active involvement and user comfort are just as important as the technical execution of a digital model.
When VR technologies are used in a familiar and controlled environment — such as a corporate training classroom or at home — the user’s interaction with the digital twin feels as natural as possible. Based on our experience, people engage with VR technology even more enthusiastically in these settings, which enhances both their learning engagement and overall effectiveness.
When VR technologies are used in a familiar and controlled environment — such as a corporate training classroom or at home — the user’s interaction with the digital twin feels as natural as possible. Based on our experience, people engage with VR technology even more enthusiastically in these settings, which enhances both their learning engagement and overall effectiveness.
Viewers Adapting to the Virtual Environment
In a traditional video, the camera moves according to a pre-defined script, allowing us to control exactly what the viewer sees in each frame. However, in a VR headset, the viewer can look in any direction they choose. It is impossible to fully predict a person’s behavior in a free simulation.
This means that if something in the interactive model is incorrectly configured — if a switch doesn’t activate, a mechanism doesn’t turn, or an expected event doesn’t happen — a trained specialist will immediately notice it. Adapting scene rendering for a VR headset required meticulous and thorough work, often demanding significantly more effort compared to traditional screen representation.
One well-known challenge of VR visualizations is that when a person puts on a headset, they enter a completely new environment and become disconnected from physical reality. The viewer may start moving blindly, risk bumping into objects or stumbling, and feel self-conscious about looking awkward. Because of this, attendees at public events, such as exhibitions, may hesitate to interact with VR experiences.
This issue can be mitigated by a well-trained booth assistant guiding the viewer, a dedicated VR area with safety measures, or VR glasses with a passthrough mode that allows users to see their surroundings when needed.
This means that if something in the interactive model is incorrectly configured — if a switch doesn’t activate, a mechanism doesn’t turn, or an expected event doesn’t happen — a trained specialist will immediately notice it. Adapting scene rendering for a VR headset required meticulous and thorough work, often demanding significantly more effort compared to traditional screen representation.
One well-known challenge of VR visualizations is that when a person puts on a headset, they enter a completely new environment and become disconnected from physical reality. The viewer may start moving blindly, risk bumping into objects or stumbling, and feel self-conscious about looking awkward. Because of this, attendees at public events, such as exhibitions, may hesitate to interact with VR experiences.
This issue can be mitigated by a well-trained booth assistant guiding the viewer, a dedicated VR area with safety measures, or VR glasses with a passthrough mode that allows users to see their surroundings when needed.
Demonstration of the “Fire in the Control Room” Algorithm
User interaction
Touch Interface of the Application
Depending on the parameters activated by the user, the station model begins to respond automatically. Alarms are triggered, pressure balancing algorithms are activated, gas supply switches from main lines to backup lines, filters are cleaned, and in cases of excessive pressure levels, the station shuts down completely and releases excess gas.
After the automatic sequence is completed, the user can manually repeat the process step by step. This is useful for clear demonstration of the system’s operation to any viewer or for employee training.
In our work, we use the Unreal Engine, which allows us to create VR visualizations of almost any complexity. Thanks to optimizations, such models can be run on affordable computer hardware and even be implemented for mobile platforms. For example, displaying the model on a UHD (4K) screen at 120 frames per second without graphical quality loss requires just Nvidia GTX 1070 graphics card.
After the automatic sequence is completed, the user can manually repeat the process step by step. This is useful for clear demonstration of the system’s operation to any viewer or for employee training.
In our work, we use the Unreal Engine, which allows us to create VR visualizations of almost any complexity. Thanks to optimizations, such models can be run on affordable computer hardware and even be implemented for mobile platforms. For example, displaying the model on a UHD (4K) screen at 120 frames per second without graphical quality loss requires just Nvidia GTX 1070 graphics card.
Frame from Commissioning Works
If you watched the video, you probably noticed that our VR model includes a touchscreen table, a display screen, and a virtual reality headset. The image on the touchscreen table is fully synchronized with the mnemonic diagram on the operator’s screen and reflects the current state of the entire gas distribution station.
The interactive models for both the screen and the headset display the station’s blocks and units, the movement of gas from entry to exit — including the gas heating circuit, pressure regulators, filters, and other equipment. All components run on multiple computers and are synchronized over a network.
This setup allows us to interact with the diagram on the touchscreen table to simulate various scenarios, including emergency situations, within the model.
The interactive models for both the screen and the headset display the station’s blocks and units, the movement of gas from entry to exit — including the gas heating circuit, pressure regulators, filters, and other equipment. All components run on multiple computers and are synchronized over a network.
This setup allows us to interact with the diagram on the touchscreen table to simulate various scenarios, including emergency situations, within the model.
How we created the VR model
Today, more and more industrial companies recognize the benefits of digital environments and twins for visually representing complex technical processes. This approach helps with employee training and business decision-making.
One such company, Gazenergokomplekt (Gas and Energy Equipment), approached us with a request. This company specializes in the development and production of gas equipment and tasked us with creating a digital twin of one of its gas distribution stations. The goal was to showcase the station to potential customers and later focus on staff training.
The visualization was designed to be as clear and detailed as possible, providing an unambiguous understanding of the space and the processes occurring under both normal and emergency conditions. Thanks to VR visualization, viewers could easily assess the actual dimensions of the equipment, realistically experience the station’s interior, and observe how the facility reacts to various situations.
Such an immersive representation fully captures a person’s attention, reveals typically hidden details, and highlights the advantages and unique features of the demonstrated model.
We developed two display options:
1. A standard on-screen demonstration.
2. A VR headset experience.
Visitors at the exhibition were immediately drawn to the large touchscreen table positioned in the walkway, while executives and chief engineers from major companies eagerly put on the headset to explore the gas distribution station in a virtual environment. Of course, some attendees declined to use the headset for various reasons, so we provided a simultaneous screen visualization for them.
One such company, Gazenergokomplekt (Gas and Energy Equipment), approached us with a request. This company specializes in the development and production of gas equipment and tasked us with creating a digital twin of one of its gas distribution stations. The goal was to showcase the station to potential customers and later focus on staff training.
The visualization was designed to be as clear and detailed as possible, providing an unambiguous understanding of the space and the processes occurring under both normal and emergency conditions. Thanks to VR visualization, viewers could easily assess the actual dimensions of the equipment, realistically experience the station’s interior, and observe how the facility reacts to various situations.
Such an immersive representation fully captures a person’s attention, reveals typically hidden details, and highlights the advantages and unique features of the demonstrated model.
We developed two display options:
1. A standard on-screen demonstration.
2. A VR headset experience.
Visitors at the exhibition were immediately drawn to the large touchscreen table positioned in the walkway, while executives and chief engineers from major companies eagerly put on the headset to explore the gas distribution station in a virtual environment. Of course, some attendees declined to use the headset for various reasons, so we provided a simultaneous screen visualization for them.
Primary and Backup Pump of the Heat Carrier Heating Circuit
About the project
As mentioned above, virtual environments or digital twins are replicas of real or designed objects. They allow for the simulation of technical and technological processes or the training of personnel behavior on an interactive model without the need to be physically present at the facility.
A digital twin is often created at an early stage, during the conceptual phase, so that all participants and collaborators can understand how the object will look and function. The demand for such virtual environments primarily comes from industrial and engineering companies.
There are three main situations where a digital twin can be useful.
According to a study, skills acquired in a simulation transfer to the real world with a high retention rate. Additionally, working in a VR environment is safe and allows for unlimited training repetitions.
According to PwC, people trained in VR simulations are 275% more confident in applying their skills compared to those trained using traditional educational programs. In its article on digital twins, Gartner reports that the future application of training virtual environments and simulations could increase the efficiency of large industrial productions by up to 10%.
A digital twin is often created at an early stage, during the conceptual phase, so that all participants and collaborators can understand how the object will look and function. The demand for such virtual environments primarily comes from industrial and engineering companies.
There are three main situations where a digital twin can be useful.
- The object does not yet exist, but there is a need for interactive visualization and accelerated design.
- The object is in a hard-to-reach location, and operating it with an untrained operator or even being inside it is dangerous (for example, a replica of a nuclear power plant or an aircraft simulation used for emergency scenario training).
- The object is a unique prototype, existing in a single copy, but a large number of people need to test it or undergo training on it.
According to a study, skills acquired in a simulation transfer to the real world with a high retention rate. Additionally, working in a VR environment is safe and allows for unlimited training repetitions.
According to PwC, people trained in VR simulations are 275% more confident in applying their skills compared to those trained using traditional educational programs. In its article on digital twins, Gartner reports that the future application of training virtual environments and simulations could increase the efficiency of large industrial productions by up to 10%.
Visualization using digital twins helps make decisions in the early stages of a project
What are digital twins and what are they used for?
Virtual reality technologies and other interactive media extend far beyond video games and leisure activities and not limited to entertainment. One notable example of using virtual environments and digital twins in the industry is NVIDIA's Omniverse project. In collaboration with BMW, they created a digital replica of the Regensburg factory to simulate large-scale production in real time.
Such digital twins (or replicas) are virtual models of objects, processes, or complex systems. They replicate the behavior of their real-world counterparts and are often synchronized with them to simulate and predict process flows based on changing conditions.
In this article, I want to share the recent experience of the interactive media production studio Gaidamaka.pro and how we created an interactive VR model of a gas distribution station for the engineering company Gazenergokomplekt (Gas and Energy Equipment). The project was presented at the St. Petersburg International Gas Forum in October 2021.
Such digital twins (or replicas) are virtual models of objects, processes, or complex systems. They replicate the behavior of their real-world counterparts and are often synchronized with them to simulate and predict process flows based on changing conditions.
In this article, I want to share the recent experience of the interactive media production studio Gaidamaka.pro and how we created an interactive VR model of a gas distribution station for the engineering company Gazenergokomplekt (Gas and Energy Equipment). The project was presented at the St. Petersburg International Gas Forum in October 2021.
If you or your company believe in the future of digital twins in industrial applications, feel free to reach out.