Process safety deviations cut by a third.
An Indian oil refinery deployed Drona VR Process Safety modules for control room and field operators. Within 90 days, process safety deviations declined by a third. Emergency shutdown rehearsals — historically annual — moved to monthly.
ESD rehearsal happened once a year. Operators forgot the sequence in three months.
Indian oil refinery
Indian oil refinery with multiple process units. Control-room and field operators across crude distillation, FCC, and hydrotreaters.
Emergency shutdown procedures were rehearsed annually in classroom drills. Reflex faded within months. Process safety deviation reports showed the same root causes recurring.
Module deployed: Process Safety + Emergency Evacuation.
Drona VR Process Safety module configured to the unit's specific shutdown sequence and deviation procedures. Monthly rehearsal cycle — feasible because each module is ~14 minutes.
Deployment timeline.
Numbers from 90 days post-deployment.
Deviation rate fell.
Process safety deviation count declined ~33% in the first 90 days post-deployment.
Rehearsal frequency.
ESD rehearsal moved from annual to monthly — twelve-fold increase, possible because modules fit shift handover windows.
Operator certification.
Every control-room operator certified within 8 weeks of deployment start.
No network impact.
Runtime entirely at the unit, no cloud dependencies.
OSHA PSM auditors started asking about training format, not just content. The Drona format gets a pass.
Three modules. One platform.
Three takeaways from this deployment.
Rehearsal frequency is the lever.
Annual rehearsal does not build reflex. Monthly does. VR makes monthly feasible.
Audit format expectations are shifting.
PSM auditors are looking at training modality, not just attendance.
Control room and field need the same drill.
Splitting drill audiences left gaps. Unified VR rehearsal closed them.
Train oil refining for the work where mistakes are audit findings.
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