Transforming Industrial Incidents into Immersive Safety Learning with Reliance Industries Limited 

Transforming Industrial Incidents into Immersive Safety Learning with Reliance Industries Limited

1. The Premise

Reliance Industries Limited (RIL), one of the world’s largest petrochemical conglomerates, continually invests in safety culture improvement at its mega-scale Jamnagar refinery complex. In April 2022, the RIL HSSE team engaged CORE-EHS to develop a series of 3D animated training videos, recreating real-life safety incidents involving process leaks and under-deposit corrosion.

The objective was to visualize these past events into self-learning modules, enabling knowledge transfer in a more retentive, scalable, and audit-compliant format.

2. The Challenges

Despite having detailed SOPs and internal training documents, RIL identified several limitations in knowledge transfer:

• Technical complexity of corrosion and leak events made verbal explanations insufficient.
• 60%+ of field-level staff lacked clarity on the chain of failure and root cause due to jargon-heavy slides.
• Traditional incident reports failed to visually convey cause-effect relationships, limiting risk perception.
• Need for standardized, visual modules that could be deployed across shifts, locations, and future batches.

The goal was to bring incident learnings to life through animation—without overwhelming the learner with technical language.

3. The Solution

CORE EHS developed three custom 3D animated videos, each tailored to a specific real-world failure event:

Topics Covered:

1. Leak in Crude Stripper Column (LG/LT Standpipes)
   Duration: ~5 minutes
   Focus: Under-deposit corrosion and inspection gaps
2. Sulfuric Acid Day Tank Pin Hole Leak
   Duration: ~4 minutes
   Focus: Equipment integrity and visual inspection lapses
3. Leak in STP Connection in Cold Service
   Duration: ~4 minutes
   Focus: Improper clamping and material degradation

Development Process:

• Collaborative scriptwriting with RIL process safety leads
• 3D modeling of actual components, environments, and leak pathways
• Narration in English with optional subtitle overlays for clarity
• Modules delivered as LMS-compatible, self-learning units

Despite technical depth, the animations were kept under 5 minutes per module to maximize attention and retention.

4. Resulting Benefits

The initiative delivered high-impact results across technical and compliance KPIs:

• Learner comprehension scores improved by 66%, validated by knowledge assessments
• Training time reduced by 45%, thanks to visual storytelling replacing long-form presentations
• Standardization across units achieved 100%, improving audit readiness
• Incident recall accuracy improved by over 70%, based on field feedback

The project became a reference framework for other refinery units, with plans to extend animation to near-miss events and process hazard analysis training.