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Highlights
A pioneering implementation of the Industrial Metaverse in the oil and gas sector, this project redefined operational intelligence, safety, and workforce training by seamlessly integrating digital twin technology, immersive XR platforms, and real-time IoT analytics. Pro Digital engineered a transformative, virtual-first operating model that now serves as a benchmark for next-gen energy infrastructure.
The Challenge
Operating in one of the most volatile and asset-intensive industries, the client needed to reduce operational risks, enhance remote decision-making, and improve the safety and readiness of on-ground personnel. Traditional methods were resource-heavy, exposed workers to physical risks, and lacked real-time insights. The leadership recognized the need for immersive, data-driven transformation to navigate these growing complexities—and turned to Pro Digital for an end-to-end Metaverse implementation strategy.
Our Solution
Pro Digital proposed a comprehensive Industrial Metaverse platform anchored by a dynamic digital twin of the client’s refinery. A crucial step in the journey was Pro Digital’s ability to extract and transform raw CAD data—specifically Navisworks files—into a fully functional, realistic, and interactive digital twin. This involved optimizing the heavy 3D models, mapping spatial hierarchies, layering IoT sensor data, and building intuitive interfaces to convert static design files into a living operational model.
Using high-fidelity 3D modeling and simulation tools, we created a real-time, interactive replica of the entire facility—enabling process optimization, emergency response simulations, and remote operations. To enhance user engagement, large-format interactive LED walls and 3D holographic displays were deployed at key touchpoints. These interfaces were powered by custom-built applications tailored for each scenario, delivering immersive content and real-time data overlays.
Extended Reality (XR) was at the core—featuring AR overlays for live maintenance guidance, VR simulations for training and safety drills, and MR tools that enabled remote experts to support on-site teams through live audio-video feeds. This end-to-end immersive system allowed stakeholders to visualize operations, collaborate remotely, and act decisively—safely and efficiently.
Our Scope Included
Pro Digital’s full-scope engagement encompassed techno-architectural consulting, spatial experience design, and complete deployment of immersive technology infrastructure. We began by taking the refinery’s CAD and Navisworks files and transforming them into a data-enriched digital twin that could interface with real-time systems. This included model optimization, level-of-detail restructuring, and integration with IoT sensors and SCADA systems for real-time monitoring and control.
Interactive LED walls and 3D holographic panels were installed to serve as immersive control points—each powered by bespoke software applications for visualization and decision-making. Augmented Reality tools were deployed to provide in-field workers with contextual overlays during critical tasks, while Virtual Reality platforms simulated hazardous training environments in a safe, controlled manner. Mixed Reality headsets enabled off-site subject matter experts to interact with field staff in real time, providing live guidance and support.
The deployment featured a full-stack custom application environment, advanced visualization systems, resilient AV/IT infrastructure, and comprehensive training and support—all designed to operate seamlessly in mission-critical industrial settings.
The Impact
40% Reduction in Operational Downtime through predictive analytics and real-time fault detection
60% Cost Savings in Training by shifting to VR-led safety simulations and onboarding
Zero-Incident Simulation Environment for high-risk procedures and emergency drills
Enhanced Remote Collaboration using MR tools, enabling off-site experts to guide frontline workers
Increased Asset Lifecycle through better monitoring, diagnostics, and proactive maintenance
Reduced On-site Risk by minimizing the need for physical presence in hazardous zones
Why It Matters
This project showcases how the Industrial Metaverse is not just a concept but a powerful operational framework. Pro Digital's integrated approach—starting from basic Navisworks CAD models to delivering a fully immersive, data-rich, operational ecosystem—demonstrates our unique ability to translate static engineering data into dynamic business intelligence. The solution enhances safety, reduces costs, and sets a new benchmark for intelligent infrastructure in energy sectors. It’s a model of how technology and design can coalesce to solve real-world industrial challenges with precision, impact, and foresight.