Industrial XR training, built in Unreal Engine.

Operating states

• Startup
• Normal operation
• Shutdown

Failure cases

• LESSLESS levelLow level switch trips the burner before the exposed fire tube reaches damaging temperature.
• NONO flowHigh bath temperature cuts the burner, and the relief valve protects the coil against thermal expansion of trapped gas.
• MOREMORE temperatureHigh temperature trip cuts fuel; relief protects the shell and the low level trip provides a second line of defence.
• NOFlame failureFlame supervision closes the fuel valve on loss of flame and forces a full purge before any re-light attempt.
• OTHER THANCoil leakGas detection alarms and the operator shuts in the unit; relief protects the bath from the pressure of the released gas.

Operating states

• Normal Production
• Standby
• Purge

Failure cases

• MOREHigh storage pressureHydrogen is relieved to atmosphere at height through the vent stack, and production stops.
• NOHydrogen leakProduction trips and the leak is limited to the volume already outside isolation.

Operating states

• Normal Operation
• Startup
• Shutdown

Failure cases

• MOREHigh separator levelFeed and compressor trip before liquid reaches the compressor suction.
• MOREColumn overpressureThe column relieves to flare and stays within its design pressure.

Operating states

• Automatic Cycle
• Reduced Speed Teach
• Safe Stop

Failure cases

• NOCell entry during cycleThe arm stops before the person is inside its reach envelope, and stays stopped until the cell is reset.
• NOLoss of drive powerThe arm holds position with its load, and the part stays in the gripper.

Operating states

• Startup and warm-through
• Normal operation
• Reduced throughput
• Controlled shutdown
• Standby and isolation

Failure cases

• NONO tube-side flowLoss of flow shows first as the tube-side outlet temperature running away from its normal value — upward where the other stream is hotter, downward where it is colder — and the operator restores flow or takes the other stream off. Where the side has been blocked in, the thermal relief inside the isolation holds the pressure while that is done; and the isolation sequence is what should have prevented a liquid-full side being shut in against heat in the first place.
• LESSLESS heat transfer (fouling)The duty loss is visible as a drifting outlet temperature together with a rising pressure drop, and the exchanger is taken off line and cleaned at a planned opportunity rather than run to failure. Inspection at that opportunity is what establishes whether the tubes have thinned as well as fouled — the process data cannot show it.
• OTHER THANTube failure between the streamsPressure falling on one side while it rises on the other is the signature, and it is alarmed: the trip takes out the higher-pressure source, the exchanger is shut in and isolated, and where the unit was designed with margin across the interface, that margin is what the lower-pressure side is holding while it happens. Where there is no margin, the relief device is carrying the rupture flow on its own.
• AS WELL ASAS WELL AS — cross-contamination through a leaking tubeComposition monitoring or routine sampling of the receiving stream picks the ingress up while it is still small — pressure instrumentation will not, and should not be credited here — and the exchanger is isolated and the leaking tubes located, plugged or replaced. Where the pressure hierarchy was set deliberately, the leak has been running into the stream that can tolerate it rather than out into a utility.
• MOREMORE rate of temperature change (thermal shock)Controlled warm-through and cool-down, at a rate that is monitored rather than assumed, keeps the differential inside what the joints can carry; the outlet temperature alarm is what tells the operator that one stream has gone while the other is still running, which is the cause that arrives without warning. Any cycle known to have run too fast is followed by inspection aimed specifically at cracked tube-to-tubesheet joints and relaxed bolting.
• OTHER THANGirth joint leak to atmosphereThe weep is found by detection or on an operator round while it is still a weep; the exchanger is proved isolated, depressurised and drained before a bolt is touched, and the joint is remade with a new gasket and controlled tightening rather than nipped up in service.