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<p>The integration of physical assets with digital technologies is central to Industry 4.0 (I4.0)-driven maintenance. In geothermal power plants, primary pumps are susceptible to cavitation-induced vibrations that reduce operational reliability. Although computational fluid dynamics (CFD) is widely used to analyze cavitation phenomena, its results are rarely accessible to field operators, while existing mixed reality (MR) maintenance tools typically lack physics-based flow insight. This study proposes a physics-informed MR maintenance support framework that integrates CFD-based cavitation analysis into an interactive digital environment for geothermal pump systems. This work does not aim to develop a novel CFD methodology; instead, the CFD results are derived from steady-state simulations supported by laboratory-scale assumptions and comparison with operational data, providing an interpretable representation of cavitation behavior. The framework embeds simulation-derived flow characteristics alongside 3D models, exploded views, real-time monitoring, technical specifications, SOPs, and maintenance checklists within a unified MR interface deployed using a Trimble XR10 device with Microsoft HoloLens 2. A user evaluation involving 50 participants demonstrated that experienced operators performed maintenance-related information retrieval tasks more efficiently than novice users, with statistical analysis confirming significant inter-group differences. Although hardware and network constraints currently limit continuous field deployment, the system is more suitable for training and assisted maintenance scenarios rather than continuous real-time deployment. Nevertheless, the proposed framework demonstrates the potential of integrating physics-based simulation into MR environments to enhance operator understanding and support maintenance-related decision-making in geothermal power plants.</p> Graphical Abstract <p></p>

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An integrated digital manufacturing solution for supporting maintenance activities on geothermal power plant

  • 期刊论文

  • 发表日期：

    2026年5月18日

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  • P. Paryanto,
  • Nur Cahyo,
  • Sefrian Imam Baskoro,
  • Vicky Ilyasa,
  • Yunus Afandi,
  • Mohammad Tauviqirrahman

摘要

The integration of physical assets with digital technologies is central to Industry 4.0 (I4.0)-driven maintenance. In geothermal power plants, primary pumps are susceptible to cavitation-induced vibrations that reduce operational reliability. Although computational fluid dynamics (CFD) is widely used to analyze cavitation phenomena, its results are rarely accessible to field operators, while existing mixed reality (MR) maintenance tools typically lack physics-based flow insight. This study proposes a physics-informed MR maintenance support framework that integrates CFD-based cavitation analysis into an interactive digital environment for geothermal pump systems. This work does not aim to develop a novel CFD methodology; instead, the CFD results are derived from steady-state simulations supported by laboratory-scale assumptions and comparison with operational data, providing an interpretable representation of cavitation behavior. The framework embeds simulation-derived flow characteristics alongside 3D models, exploded views, real-time monitoring, technical specifications, SOPs, and maintenance checklists within a unified MR interface deployed using a Trimble XR10 device with Microsoft HoloLens 2. A user evaluation involving 50 participants demonstrated that experienced operators performed maintenance-related information retrieval tasks more efficiently than novice users, with statistical analysis confirming significant inter-group differences. Although hardware and network constraints currently limit continuous field deployment, the system is more suitable for training and assisted maintenance scenarios rather than continuous real-time deployment. Nevertheless, the proposed framework demonstrates the potential of integrating physics-based simulation into MR environments to enhance operator understanding and support maintenance-related decision-making in geothermal power plants.

Graphical Abstract