AppsBow delivered a large-scale VR training program for Rafineria Gdańska (formerly Grupa Lotos), covering Plant 200 (gasoline hydrodesulfurization unit) and Plant 520. The project combined highly detailed digital twins with interactive vReact VR Training modules and the vReact Reporting system, all fully SCORM 2004–compatible and integrated with the refinery’s LMS. This allowed the client to track progress, measure performance, and manage workforce training in real time.
The training scenarios reflected real operational tasks, including pump operations, system restarts, and plant startup sequences. For Plant 200, AppsBow also developed an advanced Operator Training Simulator (OTS) dedicated to the full startup procedure of the plant. By recreating critical operations such as switching pumps, preparing equipment for maintenance, or restarting the turbocompressor, the solution enabled refinery operators to practice safely in a hyper-realistic environment, minimizing risk, preventing costly errors, and ensuring readiness for high-stakes operations.
Scope of work
- VR training for plant 200 - gasoline hydrodesulfurization unit
- VR training for plant 520
- Digital twins for plant 200 and plant 520
- Operator Training Simulator
- vReact Report system
- vReact stage learning system
- LMS integration for VR training
Overview
As part of the project, AppsBow created a range of VR training scenarios that reflected real refinery operations. These included, among others, pump operations, system restarts, equipment preparation, and complete plant startup sequences across Plant 200 and Plant 520.
Plant 200 scenarios
- Switching to circulation
- Switching pumps
- Preparing a pump for maintenance
- Checking the pressure gauge
- Starting up the installation
Plants 520 scenarios
- Preparing, starting, and switching pump
- Restarting pump
- Restarting turbocompressor
- Starting up the sealing and oil system
- Heating up and startup
vReact staged learning system
The project also introduced a three-stage learning system to ensure effective skill progression. Stage 01 offered a guided mode with a task list and points of interest to support operators step by step. Stage 02 shifted to task mode, where only the task list was available, encouraging users to perform actions with less assistance. Finally, Stage 03 functioned as an exam mode, with no hints or task list, requiring operators to complete procedures independently and demonstrating full readiness for real operations.
vReact Report System
The project was complemented by the implementation of a comprehensive reporting system designed for both trainers and managers. Accessible through a browser via local intranet or the internet, the dashboard offered full control over user and group accounts, with access permissions and security restrictions configurable by IP or MAC address. Training performance was tracked in detail, with both text and graphical statistics covering user activity, completion rates, time spent, and mistakes. Reports could be exported in multiple formats, including .txt, .xml, and .pdf, making documentation and sharing straightforward. An optional leaderboard feature added a layer of motivation through friendly competition. Importantly, the system was fully compatible with open-source eLearning platforms, ensuring seamless SCORM 2004 (or newer) integration and long-term scalability.
Operator Training Simulator implementation
For Plant 200, AppsBow developed a dedicated Operator Training Simulator (OTS) focused on the debutanizing process. The simulator recreated the complete startup sequence of the unit in a hyper-realistic digital twin environment, allowing operators to follow every step as they would on the real installation.
Flexible Access Options
The system was designed to operate not only with a VR headset but also with a mouse and keyboard in a traditional desktop setup. This flexibility ensured that training could be delivered both in fully immersive environments and through standard computer interfaces, making it accessible to a wider range of users and adaptable to different training conditions.
vReact - video example of training
vReact in-app screenshots
