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.

Operating states

• Charged, engine off
• Normal operation
• Engine running, A/C off
• Clutch cycling
• Recovered for service

Failure cases

• MOREMORE discharge pressureThe cut-out releases the clutch and the system stops cooling until the pressure falls — warm air at idle, for the driver — and the technician traces the cause to the fan, the condenser or the charge.
• LESSLESS refrigerant charge (leak)The low-pressure cut-out stops the compressor running on a low charge. Cooling is lost, the leak is found with a detector or dye at service and repaired, and the circuit is evacuated and charged by weight.
• AS WELL ASAS WELL AS liquid at suctionEvaporator temperature control cycles the clutch or cuts capacity before the evaporator ices, and a charge weighed in to specification leaves no excess liquid to come back.
• OTHER THANOTHER THAN procedure — opened while chargedRecovery before the circuit is opened leaves nothing behind the joint, eye and hand protection deal with the residue, and the work is done in a ventilated bay away from pits and ignition sources.
• MOREMORE clutch slipThe slip is found at service, with the air gap and the coil supply checked against the vehicle data, and the clutch or the connector is put right before the bearing is damaged.

Operating states

• Charged, high voltage off
• Normal operation
• Parked or charging
• High voltage isolated
• Recovered for service

Failure cases

• MOREMORE discharge pressureThe control system slows or stops the compressor and cooling falls until the pressure comes down; the cause is traced to the fan, the condenser or the charge.
• LESSLESS refrigerant charge (leak)The protection stops the compressor running on a low charge. The leak is found with a detector or dye and repaired, and the circuit is evacuated and charged by weight.
• OTHER THANOTHER THAN specified oil (insulation)The insulation monitoring flags the fault before it is a hazard; the circuit is flushed to the manufacturer's procedure, or the compressor replaced, and recharged with the specified oil.
• OTHER THANOTHER THAN procedure — high voltage not isolatedIsolation by the vehicle's procedure, with absence of voltage proved, means there is nothing live at the connector when it is touched.
• OTHER THANOTHER THAN procedure — opened while chargedRecovery before the circuit is opened leaves nothing behind the joint, eye and hand protection deal with the residue, and the work is done in a ventilated bay away from pits and ignition sources.

Operating states

• Charged, engine off
• Normal operation
• Engine running, A/C off
• Recovered for service

Failure cases

• MOREMORE discharge pressureThe control cuts the displacement and cooling falls until the pressure comes down; the cause is traced to the fan, the condenser or the charge.
• LESSLESS refrigerant charge (leak)The fault is logged and the leak found with a detector or dye at service, repaired, and the circuit evacuated and charged by weight before the compressor has run dry for long.
• AS WELL ASAS WELL AS liquid at suctionEvaporator temperature control holds the evaporator off freezing, and a charge weighed in to specification leaves no excess liquid to come back.
• MOREMORE drive torque (seizure)The torque limiter gives way, the belt keeps driving the other accessories, and the vehicle is driven or recovered to have the compressor replaced and the circuit flushed.
• OTHER THANOTHER THAN procedure — opened while chargedRecovery before the circuit is opened leaves nothing behind the joint, eye and hand protection deal with the residue, and the work is done in a ventilated bay away from pits and ignition sources.

Operating states

• As supplied
• Being fitted
• First start
• Removed from service

Failure cases

• MOREMORE pressure behind the capsEased off slowly and facing away, the cap vents the charge as a hiss, and eye protection deals with any oil.
• OTHER THANOTHER THAN specified oil or quantityThe oil is checked and set to the instructions on the bench, before the compressor goes in.
• AS WELL ASAS WELL AS oil in the chambers at first startTurned by hand first, the compressor clears its chambers and starts against vapour, as it should.
• AS WELL ASAS WELL AS debris from the old compressorFlushed, with the drier and expansion device replaced, the circuit gives the new compressor clean oil and refrigerant to run on.
• AS WELL ASAS WELL AS moistureCaps stay on until each line is fitted, and the circuit is evacuated and held before it is charged.

Operating states

• Clean element
• Normal operation
• Wading or heavy rain
• Element change

Failure cases

• LESSLESS airflow (blocked element)The element is changed when it is due, and the engine keeps its airflow.
• OTHER THANOTHER THAN filtered air (bypass)The seal and the latches are checked after every element change, and no dust reaches the clean side.
• AS WELL ASAS WELL AS water in the intakeThe vehicle stays within its wading limit, and any water that reaches the housing stays on the dirty side.
• OTHER THANOTHER THAN procedure — engine run with the intake openThe engine stays off until the housing is closed and every latch checked.

Operating states

• Stowed
• In use
• Running at speed
• Examination and test

Failure cases

• NONO extraction flowThe airflow indication shows the fan is not running before the engine starts, or the detector alarms, and the engine is stopped.
• LESSLESS capture at the tailpipeThe nozzle matches the tailpipe and is checked on, and the exhaust is captured.
• OTHER THANOTHER THAN intact hose (split or crushed)The damage is seen at the pre-use check and the hose replaced before it is used again.
• MOREMORE exhaust temperatureHeat-resistant gloves are used, and heat-damaged hose is found and replaced.
• OTHER THANOTHER THAN procedure — vehicle moved with the nozzle onThe nozzle comes off and the hose is reeled in before the vehicle moves.

Operating states

• Out of hours
• Occupied
• Fire alarm
• Maintenance at height

Failure cases

• NONO escape route (blocked or locked)Daily checks keep the routes clear and the doors openable, and drills prove it.
• LATELATE warning of fireThe first person to find the fire raises the alarm at the nearest call point and everyone hears it.
• MOREMORE load on the galleryThe safe working load is displayed and enforced, and the gallery is kept clear.
• NONO edge protectionGuardrails stay fixed and complete, and any removal is planned with the edge protected another way.
• AS WELL ASAS WELL AS vehicle impactVehicles are kept away from the structure by layout and barriers, and any strike is reported and inspected before the structure is used.

Operating states

• Being fitted or serviced
• In service
• Released
• After a discharge

Failure cases

• LESSLESS stored pressureThe low reading is seen at a pre-use check and the cylinder is serviced before the vehicle is used.
• NONO discharge on demandA serviced, armed system discharges when released; and an operator who knows the system is only a delay is already getting out.
• OTHER THANOTHER THAN intended — unintended dischargeWith the release made safe for the work, nothing discharges; if it does, the space is ventilated and left until it is clear.
• OTHER THANOTHER THAN secure mountingTight, sound mounting holds the cylinder where it was fitted through vibration and impact.

Operating states

• Being fitted or serviced
• In service
• Released
• After a discharge

Failure cases

• OTHER THANOTHER THAN intact hoseThe damage is found at an inspection and the hose replaced before the vehicle is used.
• NONO discharge on demandA serviced, armed system discharges when released; and an operator who knows the system is only a delay is already getting out.
• OTHER THANOTHER THAN intended — unintended dischargeWith the release made safe for the work, nothing discharges; if it does, the space is ventilated and left until it is clear.
• OTHER THANOTHER THAN secure mountingTight, sound mounting holds the cylinder where it was fitted through vibration and impact.

Operating states

• Open
• Closed
• Isolating for maintenance
• Being opened or closed

Failure cases

• MOREMORE flow through a closed valve (passing)The bleed shows the valve is passing before anything is opened, and the isolation is extended.
• NONO movement when operatedThe valve is found stiff during routine exercising and freed or repaired while it is not needed.
• OTHER THANOTHER THAN containment: leak at the glandThe weep is seen on inspection and the gland adjusted or repacked under a permit.
• OTHER THANOTHER THAN containment: flange leakThe leak is found early, the line isolated, and the joint remade with a new gasket.
• OTHER THANOTHER THAN the intended valve operatedThe number is checked against the permit and the mistake caught before the wheel is turned.