Every drill starts the way a real bad night does: a shift handover, then trouble. Each one has an answer key built from real operating practice, with the right moves, the tempting wrong moves, and hard safety rules.
Showing all 23 drills
HandoverNight shift reports a stable kiln. Two minutes ago the kiln drive jumped and the shell scanner shows a warm band near pier 2. Production wants you to hold full feed.
TrainsReading kiln amps against NOx, and protecting the shell while coating builds back.
HandoverOver the last hour kiln drive amps have crept up. The ID fan is working harder at the same feed. O2 looks steady. The last operator added a bit of fuel "to burn it off".
TrainsTelling a ring from false air, and slowing ring growth before it shuts the kiln.
HandoverA known ring has been growing for two days. The field operator is at the clinker discharge checking the breaker. Suddenly a lot of alarms come in at once.
TrainsProtecting people and the cooler when a ring lets go.
HandoverThe raw mix changed at the blending silo an hour ago and is harder to burn. NOx has been dropping and the last free lime came back high.
TrainsCatching a cooling kiln early, before the lab result tells you.
HandoverNight shift pushed fuel to fix high free lime and never took it back off. The lab just called: free lime is very low. Shell temperatures are creeping up.
TrainsTaking heat out of an overburned kiln and saving the fuel it wastes.
HandoverAfter a primary air fan problem, the flame looks unsteady on the kiln camera. Burning zone temperature jumps around and CO keeps hitting 150 ppm.
TrainsFinding the cause of an unsteady flame instead of chasing the swings.
HandoverThe kiln is back after a repair stop and has run at half feed for an hour. Everything is steady. Production wants full feed as soon as it is safe.
TrainsRamping from half to full feed safely, in far less time than small steps and long waits.
HandoverA new load of shredded plastic fluff started feeding the main burner 30 minutes ago. Management wants as much alternative fuel as possible today. BZT, O2 and CO are swinging.
TrainsRunning alternative fuel hard without upsetting the kiln.
HandoverStage-4 pressure drop has crept up over the shift and gas flow is lower at the same fan speed. Calciner CO is going up and down. Calciner fuel was raised earlier.
TrainsSpotting buildup early and fixing its cause, not just the draft.
HandoverA new petcoke shipment started to the calciner 20 minutes ago. The tertiary air damper was closed down some last shift. Calciner CO alarms are coming in.
TrainsHandling calciner CO safely when air runs short.
HandoverCO has gone up and down all shift, higher each time. Each time, the last operator bumped the ID fan up. It keeps coming back worse.
TrainsBreaking a CO and draft spiral that makes itself worse.
HandoverStage-4 outlet temperature is moving away from stage 3. Kiln inlet temperature is climbing. The feed meter still reads steady.
TrainsRecognizing a hung cyclone, clearing it the approved way, and readying the kiln for the meal dump.
HandoverA richer petcoke blend started to the calciner 15 minutes ago. Last shift moved the meal split gate toward the riser. The calciner outlet is climbing toward its high alarm.
TrainsUsing the meal split and calciner fuel for the jobs each one does.
HandoverClinker discharge temperature is climbing and the bed looks uneven. Hood pressure has been creeping toward zero.
TrainsCatching a snowman early and breaking it up with people kept safe.
HandoverHot, dusty kiln since midnight. Clinker discharge temperature is high and secondary air temperature is jumping around.
TrainsGetting cooling back with fine clinker, without pouring on air everywhere.
HandoverVery coarse clinker for the last hour. The cooler is in undergrate pressure auto. Pressure is falling and grate drive amps are climbing.
TrainsControlling the cooler when coarse clinker fools the pressure reading.
HandoverThe coal mill is running hot after a switch to wet coal. Filter CO is climbing. A field operator asks if he should open the inspection cover to look.
TrainsHandling a smoldering mill without putting anyone at risk.
HandoverMaintenance worked on the compressed air system this morning. Kiln baghouse DP is rising and the ID fan is struggling to hold draft.
TrainsFinding the cause of high baghouse DP before forcing more flow.
HandoverThe raw mill is down and the gas conditioning tower cannot keep up. Baghouse DP just dropped and stack opacity is rising.
TrainsResponding to torn bags and an emissions event, including the report.
HandoverNormal running. The raw mill is grinding on kiln exhaust gas. Stand by.
TrainsProtecting the baghouse and holding the kiln when the raw mill trips.
HandoverLightning storm over the substation. The lights flicker.
TrainsGetting safe first, then restarting in the right order.
HandoverThe ID fan inlet damper has been getting dirty. Draft is swinging and fan vibration is climbing. Production wants you to hold the rate.
TrainsKeeping the kiln on when the ID fan surges.
HandoverExit O2 has read high all shift, but the flame looks lazy and the ID fan is working harder than usual. The last operator raised the fan to "give it more air".
TrainsFinding false air hiding behind a good O2 reading.
Difficulty runs Easy, Medium, Hard, Expert. Safety drills carry hard rules: break one and the run fails, however good the rest was. P-05 appears when the plant model has a downdraft calciner.
Hints, a "next move" button and a voice coach that talks like a good shift supervisor. Every run ends with a debrief next to an expert's run of the same problem.
Test mode removes all help and changes how strong the problem is and how far along it starts. A pass means they know it, not that they remember it.
20 to 60 simulated minutes with two to four problems at random times, so operators learn to spot trouble without being told a drill has started.
Plants can add custom drills for their own known trouble spots, or replay a real upset from their historian data.
Try CCR Academy in your browser today on our standard kiln line. Buy a short pass and go straight to the control room. For a version set up like your plant, book a live demo.
