Client: International Engineering, Technology & EPC Company
Sector: EPC · Process technologies · Fertilizers · Operator Training Simulation
Technology: Gilgamesh · 3D Digital Twin · OTS · OPC DA/HDA · Dynamic process model
Engagement: 3D immersive training simulator project (UREA plant)
Built on Gilgamesh, this immersive training simulator covers the Melt and Granulation sections of a UREA plant, integrated with an Operator Training Simulator driven by a dynamic process model.
The Challenge
The customer needed an immersive 3D training solution reproducing the process areas of a pilot plant, letting field operators explore the layout, locate units and execute standard and emergency procedures interactively.
A key requirement: integrate the 3D system with the Operator Training Simulator so simulator values appear in the 3D scene and trainee field actions feed back to the simulator — enabling combined control-room and field training.
The Kairos3D Solution
Kairos3D delivered a Gilgamesh-based immersive training simulator: first-person navigation, equipment interaction, contextual information, task lists, error feedback and scored scenarios covering both standard and emergency procedures. The 3D environment connects to the OTS via OPC DA (and OPC HDA where historical data helps), acting as a field-side immersive interface — indicators, valves and dynamic values stay synchronized with the process simulation while trainee actions return to the simulator. Scenario logic was authored in the Gilgamesh Module Editor.
Results
- Realistic UREA plant replica — Melt and Granulation sections reproduced for interactive training.
- True OTS integration — 3D field actions and simulator values synchronized via OPC.
- Cause-and-effect realism — Trainees experience how field operations affect process behaviour.
- Standalone + integrated training — From familiarization to full control-room-plus-field sessions.
- Structured scenarios — Task tracking and scoring for standard and emergency procedures.
- Extensible twin — A base for alarms/events, maintenance data and collaborative visualization.
Why Kairos3D
By connecting the 3D digital twin to an OTS built on the dynamic process model, Gilgamesh unifies field actions, process behaviour and control-room simulation in one training context — reducing field-training risk, standardizing procedures and creating a reusable digital asset. Following a competitive evaluation of several leading Digital Twin platforms, Gilgamesh was selected for its exceptional flexibility and was described by the customer as “the Ferrari” of Digital Twin platforms.