Bringing tomorrow’s energy facility to life: a digital twin and XR training approach

The rapid evolution of advanced simulation and immersive technologies has enabled innovative approaches for planning and training in large-scale industrial facilities. This paper presents the development of a digital twin and extended reality (XR) trainer for a portion of an energy facility that has yet to be constructed. The digital twin incorporates high-resolution 3D CAD models and system schematics, offering stakeholders a comprehensive view of future layouts and workflows. Using the same core data, an XR-based simulator immerses personnel in realistic operational environments, letting them rehearse procedures or troubleshoot designs months—or even years—before a single brick is laid. Early adoption of this digital twin/XR solution has yielded notable benefits in workforce preparedness, project risk reduction, and design optimization. By identifying potential engineering or process flaws in a virtual environment, teams can adjust strategies well in advance, ultimately saving significant time and resources. This paper details the technical architecture of the solution and explores its immediate and long-term implications for energy-sector projects and other mission-critical facilities.