McKMcK Cementmckcement.com View the presentation →

Prepared for Heidelberg Materials · HROC · October 2026

CCR Academy: simulator guide and training courses

How the control room simulator works, what your operators practice on it, and the courses we run with it for new and developing control room operators.

23 drills8 simulator courses2 instructor-led sessionsEnglish & SpanishRuns in a browser

01 · Summary

A kiln control room simulator, built by a cement man.

CCR Academy is a kiln control room simulator that runs in a web browser. Operators sit a real shift on a live control screen. A problem hits. They read the trends, call what is wrong and make their moves. Then a coach explains what went well and what to work on, in plain words.

What it is

23 drills on the kiln, preheater, cooler, mills and utilities. A coach after every drill, by text or voice. English and Spanish. A readiness record for every operator.

Who it is for

New and developing control room operators and Optimization Specialists, field operators moving up, kiln coaches and trainers, and the managers who sign people off.

How it is delivered

Any modern web browser. Nothing to install. It never connects to your DCS or plant network.

A mistake on the simulator costs nothing. The same mistake on a kiln can cost a trip and a day of clinker. CCR Academy lets operators make that mistake here first.

02 · How a drill works

Handover. Upset. Response. Debrief.

Every drill starts the way a real bad night starts: quietly, then all at once.

  1. The handoverThe operator gets a shift handover: what has been running rough, what the lab said, what to watch.
  2. The upsetAlarms sound, trends move, the field operator radios in. The kiln responds with real lags, noise and interlocks.
  3. Call it and actThe operator says what is wrong and moves fuel, feed, fans, kiln speed and dampers. Wrong moves have consequences.
  4. The debriefThe coach explains what happened and shows the operator's run next to an expert run of the same problem.

Standard drills take 10 to 20 minutes. Longer versions run up to 45 or 60 minutes, so a crew can fit a drill into the start of a shift or run a full session with a trainer.

03 · What the operator works with

The screens and tools of a real control room.

Process graphic

The kiln line from preheater to cooler. Click a piece of equipment to open its faceplate and make a move, the way you would on a DCS.

Alarms

Alarms by priority, with a horn that keeps sounding until acknowledged, and silence and acknowledge controls.

Trend screen

A separate trend page for a second monitor, with 2, 4 or 6 panels and 5 to 60 minute windows.

Field and Comms

The operator sends the field operator to check equipment by radio and reads the reply. A second trainee can join from a phone with a 4-digit code and play the field role.

Coach

Hints, a next move button, and a coach operators can ask questions by text or voice. Written in plain, simple words.

Language and units

One button switches the whole simulator, the coach and the voice to Spanish. US units by default, with a metric switch.

04 · Training modes

Practice, then prove it.

ModeWhat it does
PracticeHelp is there when the operator needs it: progressive hints, a next move button that points to the right control, and a show root cause button. Each one costs points, so leaning on help shows in the grade.
TestNo help, no alarm guide, no voice coach. The upset comes in stronger or weaker (0.85 to 1.2 times) and further along, different every run. A pass means the operator knows it, not just remembers it.
Shift run20 to 60 simulated minutes with 2 to 4 problems at random times. Operators learn to spot trouble without being told a drill has started.
Two-person drillA board operator and a field operator on a phone work the same upset together over the radio.
Plant data replayAn instructor loads a historian CSV of a real event. Operators watch it unfold, call it, then see what really happened and what the crew did.
Expert overlayAfter a run, the textbook run of the same drill is drawn over the operator's own trends.
Personal planEach operator gets a plan that repeats what they missed and spaces out reviews at 3, 7, 14 and 30 days so it sticks.

05 · Drill library

23 drills. The problems that cost plants money.

Each drill has an answer key built from real operating practice: the ideal moves, the tempting wrong moves, and the hard safety rules. Plants can add custom drills for their own known trouble spots.

CodeDrill
Kiln · 8
K-01Coating collapse, kiln amp spike
K-02Clinker ring forming
K-03Ring collapse and material surge
K-04Cold kiln, high free lime
K-05Hot kiln, overburning
K-06Unstable burner flame
K-07Kiln startup, ramp to full production
U-04Alternative fuel swings
Preheater · 5
P-01Cyclone buildup forming
P-02High CO at calciner, short of air
P-03Preheater false air spiral
P-04Cyclone jam, meal not reaching kiln
P-05Downdraft calciner running hot (downdraft calciner plants)
Cooler · 3
C-01Snowman at cooler inlet
C-02Red river, poor clinker cooling
C-03Cooler undergrate pressure drop
Mills · 4
M-01Coal mill fire risk, rising CO
M-02Baghouse DP spike, cleaning fault
M-03Baghouse bag failure, dust breakthrough
M-04Raw mill trip, kiln interaction
Utilities · 3
U-01Power dip, partial trip recovery
U-02ID fan surge, draft loss
U-03False air leak

06 · Training courses

Courses for control room operators.

This is our standard catalog. Eight courses run on the simulator, and two are led by an instructor. We tailor each one to HROC's sign-off levels, your plants and your procedures before a cohort starts.

Times are typical. Most upset drills take about 15 minutes per attempt. Plan on 2 to 3 practice attempts per drill, then a test.

Simulator courses

CCR 100

Control Room Foundations

For new hires with no cement background. Reading the board and alarms, the kiln line from preheater to cooler, normal running targets (burning zone, O₂, CO, free lime), the shift handover and talking to the field.

For
New operators and Optimization Specialists in their first weeks
Format
Self-paced on the simulator, help allowed, with a trainer checking in
Typical time
4 to 6 hours over 1 to 2 weeks
Drills
K-07 startup ramp, K-04 cold kiln, K-05 hot kiln, plus a 20-minute shift run
Assessed by
Completing each drill with help allowed, then one 20-minute shift run
CCR 110

Kiln and Burning Zone

Coating and rings, cold and hot kilns, flame problems and alternative fuel swings. Reading amps, burning zone temperature, O₂, CO and free lime together.

For
Operators who have finished CCR 100
Format
Self-paced practice, then tests
Typical time
5 to 7 hours over 2 weeks
Drills
K-01 K-02 K-03 K-04 K-05 K-06 U-04
Assessed by
B or better in practice, then a pass in test mode on each drill
CCR 120

Preheater and Calciner

Cyclone buildups and jams, high CO at the calciner, false air, and a downdraft calciner running hot.

For
Operators who have finished CCR 100
Format
Self-paced practice, then tests
Typical time
3 to 5 hours over 1 to 2 weeks
Drills
P-01 P-02 P-03 P-04 P-05 (P-05 on downdraft calciner plants only)
Assessed by
B or better in practice, then a pass in test mode on each drill
CCR 130

Clinker Cooler

Snowmen at the inlet, red rivers and poor cooling, and undergrate pressure problems.

For
Operators who have finished CCR 100
Format
Self-paced practice, then tests
Typical time
2 to 3 hours over 1 week
Drills
C-01 C-02 C-03
Assessed by
B or better in practice, then a pass in test mode on each drill
CCR 140

Mills and Dust Collection

Coal mill fire risk, baghouse faults and bag failures, and a raw mill trip and what it does to the kiln.

For
Operators who have finished CCR 100
Format
Self-paced practice, then tests
Typical time
3 to 4 hours over 1 week
Drills
M-01 M-02 M-03 M-04
Assessed by
B or better in practice, then a pass in test mode on each drill
CCR 150

Trips and Utilities

Power dips and partial trip recovery, ID fan surge and draft loss, and false air leaks.

For
Operators who have finished CCR 100
Format
Self-paced practice, then tests
Typical time
2 to 3 hours over 1 week
Drills
U-01 U-02 U-03
Assessed by
B or better in practice, then a pass in test mode on each drill
CCR 200

Shift Readiness

Putting it together. Shift runs with problems at random times, two-person drills with a field operator on a phone, and test mode on every safety drill.

For
Operators who have finished the upset courses
Format
Shift runs and tests, with a trainer for the two-person drills
Typical time
6 to 10 hours over 3 to 4 weeks
Drills
Shift runs (20 to 60 minutes), two-person drills, tests on all safety drills
Assessed by
The readiness rule below, ending in the readiness sign-off
CCR 210

Learning From Your Own Events

Instructor-led. Load a historian CSV of a real upset at one of your plants. Crews watch it unfold and call it, then see what happened and what the crew on shift did.

For
Signed-off operators and crews, as an ongoing refresher
Format
Instructor-led session, in person or remote
Typical time
1 to 2 hours per event
Drills
Your own events, loaded as plant data replays
Assessed by
Discussion with the instructor; the operator's call is recorded

Instructor-led sessions

Workshop

Cement Process Fundamentals

Led by Gerry McKervey. Pyroprocessing basics, burnability and free lime, combustion and draft, coating and rings, the clinker cooler, and how a move in one place shows up in another.

For
New operators, alongside CCR 100
Format
On site or remote
Typical time
1 to 2 days
Session

Kiln Coach Onboarding

For the trainers and kiln coaches who will run the program. Using the instructor console, reading crew readiness, setting the readiness rule to your levels, and loading plant data replays.

For
Trainers, kiln coaches and supervisors
Format
Remote or on site
Typical time
Half a day

Sample 12-week path for a new Optimization Specialist

This path sits inside HROC's existing 6 to 8 month ramp. It does not replace it. We set the order and pace with your training lead.

WeeksCoursesGoal
1 to 2CCR 100 and the Cement Process Fundamentals workshopRead the board, know normal, run a calm shift
3 to 4CCR 110Handle kiln and burning zone upsets
5 to 6CCR 120 and CCR 130Handle preheater, calciner and cooler upsets
7 to 8CCR 140 and CCR 150Handle mill, dust collector, trip and utility upsets
9 to 12CCR 200Shift runs, tests and the readiness sign-off
AfterPersonal plan refreshers and CCR 210 replaysKeep skills fresh on the upsets that rarely happen

07 · Scoring and readiness

Graded the same way, every run, every plant.

  • Every drill is graded on safety, economy (fuel and air used per ton) and production.
  • Shift runs are graded on safety, steady running and speed of response.
  • Hard safety gates. Break a hard safety rule and the run fails its safety gate, whatever else went right.
  • Help costs points: a hint costs 0.5, next move 1.5, show root cause 3.

When an operator counts as Ready

Ready means all four

Every safety drill at B or better. Three or more tests passed. A shift run at B or better. No safety gates in the last 30 days.

Three states

ReadyCloseNeeds work
Shown for every operator, by crew. We can set the rule to match your sign-off levels.

Training records print and export to CSV to support an MSHA Part 46 training program. They do not by themselves show compliance. Your competent person signs.

08 · Instructor and manager tools

Know who is ready before the kiln finds out.

Instructor console

Every operator's progress, with a crew filter.

Readiness board

Ready, Close or Needs work per operator, plus a weekly trend.

Training records

Printable records and CSV export for each operator.

Plant settings

Plant profiles, screen style per plant, and the replay loader for historian data.

09 · Tailoring to your plants

Tuned to your kiln lines, reviewed by your people.

The simulator ships with a standard kiln line. For HROC we set it up like your plants, and your training lead reviews it before any cohort starts.

What the model covers

4, 5 or 6-stage preheaters. In-line or downdraft calciners. Alternative fuels at the burner or calciner, including whole tires. Your screen colors.

What we need from HROC

Which plants come first. Preheater stages and calciner type. The cooler. Fuels and alternative fuels. Screenshots of your control screens. Optionally, one historian case from a real upset.

Who checks it

Your training lead runs the drills on your kiln and checks the trends look like home. We adjust until they sign off.

10 · Requirements

What you need to start.

ItemDetail
ComputerAny computer with a modern web browser and internet access. A large screen works best.
Second monitorOptional, for the trend screen, so it feels like the real control room.
PhoneOnly for the field role in two-person drills.
InstallationNone. Nothing is installed.
Plant systemsIt never connects to your DCS or plant network. Replays use a CSV file you choose to export.
Data storedOperator names, drill results and training records.
Sign-inSingle sign-on with your identity provider is planned.

11 · Questions

Common questions.

Does it replace our trainers or the simulator we already have?

No. It gives your trainers a better tool and adds daily practice and readiness evidence between classes. Simulators deliver the most inside a structured program with clear goals and evaluation, and we help you set that up.

How realistic is the kiln model?

The model is built around how real kilns behave: time lags between a move and its effect, noisy readings, equipment limits and burner safety interlocks. It is a training model built around the drills, not a digital twin. For your plants we tune it to your preheater, calciner, cooler and fuels so the trends look like home.

Can we add our own drills?

Yes. Plants can add custom drills for their own known trouble spots, and you can replay real events from your historian.

Does it work in Spanish?

Yes. One button switches the whole simulator, the coach and the voice to Spanish.

How long does a drill take?

Most drills run 10 to 20 minutes, with longer options up to 45 or 60 minutes. Shift runs are 20 to 60 simulated minutes.

What do we need to get started?

A computer with a browser, the list of plants to start with, and the plant details in section 09. We tune the first plant profile and your training lead reviews it.

12 · Contact

Talk to the people who built it.

Gerry McKervey, Owner, McK Cement

Gerry managed five cement plants over a 40-year career, including Lehigh Cement's Mason City, Iowa plant from 2005 to 2008. CCR Academy puts that experience in front of every operator, on every shift.

gerry@mckervey.com mckcement.com