Pregenesis Protocol — Engineering Design Package

Shredder Train — ASI Procurement Package

Modules 1–4 | Primary Shredder, Hammermill, Ash Pulverizer, Rotational Mixer & Regenesis Feed Train | Complete OEM fabrication and FAT specification

Doc No.CBT-EDP-SHRD-001

RevisionRev 0

OER ClassClass 2 ±15%

ClassificationConfidential

Document Number	`CBT-EDP-SHRD-001`
Parent TDS	CBT-PRE-TDS-003 Rev 1 — Pregenesis Shredder Train
ICD Reference	CBT-PRE-ICD-001 Rev 1 — Interface Control Document
FMEA Reference	CBT-PRE-FMEA-001 Rev 0 — FMEA Register
Governance Prompt	EDP.prompt.md v1.0 — applied to this document
ASI Scope	Factory assembly of all Shredder Train skids to Carbotura OEM specification; FAT per Section 6; Unitized Warranty Passport issued on FAT sign-off
Chairman	Allen Witters

ASI Completeness Requirement

This EDP must be complete enough that the Authorized Strategic Integrator (ASI) can fabricate, assemble, and FAT the Shredder Train module without asking Carbotura Engineering a single question. Any gap in this EDP is a procurement risk and a schedule risk. Open items are tracked with named gates per ICD Rev 1 Open Actions.

1. Equipment Identity & ASI Scope

Equipment Item	Tag Numbers	ASI Scope	Serial No. Format
Tire Pre-Shredder	`SHRD-TPS-001/002`	Supply, skid-mount, factory-wire, FAT	CBT-SHRD-TPS-[001/002]-[Year]
Primary Shredder + Spring Isolation	`SHRD-SHR-001/002`	Supply, skid-mount, inertia base pour, spring isolation install, factory-wire, FAT	CBT-SHRD-SHR-[001/002]-[Year]
Magnetic Ferrous Sep. Stage 1	`SHRD-MFS-001/002`	Supply, conveyor-mount, factory-wire, FAT	CBT-SHRD-MFS-[001-004]-[Year]
Hammermill + Spring Isolation	`SHRD-HMR-001/002`	Supply, skid-mount, inertia base pour, spring isolation install, factory-wire, FAT	CBT-SHRD-HMR-[001/002]-[Year]
Magnetic Ferrous Sep. Stage 2	`SHRD-MFS-003/004`	Supply, conveyor-mount, factory-wire, FAT	CBT-SHRD-MFS-[001-004]-[Year]
Ash Pulverizer (VRM)	`SHRD-APZ-001/002`	Supply, skid-mount, ATEX enclosure integration, factory-wire, FAT	CBT-SHRD-APZ-[001/002]-[Year]
Ash Storage Silos	`SHRD-ASL-001/002`	Supply, foundation bolt pattern, bin vent filter install, factory-wire, FAT	CBT-SHRD-ASL-[001/002]-[Year]
Loss-in-Weight Feeders	`SHRD-LWF-001/002/003/004`	Supply, skid-mount, gravimetric calibration at FAT, factory-wire	CBT-SHRD-LWF-[001-004]-[Year]
Rotational Mixer	`SHRD-MXR-001/002`	Supply, skid-mount, factory-wire, FAT blend uniformity test	CBT-SHRD-MXR-[001/002]-[Year]
Regenesis Feed Metering Bin	`SHRD-RFB-001/002`	Supply, skid-mount, level instrument install, factory-wire, FAT	CBT-SHRD-RFB-[001/002]-[Year]
Enclosed Belt Conveyors (all)	`SHRD-CV-001 through -007`	Supply, assembly, APS flange weld, factory-wire	CBT-SHRD-CV-[001-007]-[Year]

2. Design Standards & Applicable Codes

Standard	Application
`NFPA 652 (2019)`	Combustible Dust — primary governing standard for ash pulverizer zone (Z-03/Z-04)
`NFPA 68 (2018)`	Explosion Protection by Deflagration Venting — ash pulverizer, silos, hammermill
`NFPA 91 (2015)`	Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and Particulate Solids — all APS conveyor enclosures
`NFPA 70 (NEC) Art. 500–502`	Electrical — Class II Div 1 and Div 2 requirements for APZ/ASL zones
`CEMA Belt Conveyor Standards`	All enclosed belt and drag-chain conveyors; transfer chute design
`ISO 10816-3`	Mechanical vibration — spring isolation FAT verification and SCADA alarm setpoints
`ANSI/ISA-84.00.01 (IEC 61511)`	Safety Instrumented Systems — all SIL 1 interlock functions (N₂ low-flow, E-stop chain)
`OSHA 29 CFR 1910`	General industry — LOTO (1910.147), machine guarding (1910.212), confined space (1910.146)
`ANSI/ISA-5.1-2024`	Instrumentation Symbols and Identification — all instrument tags
`IBC 2021 Chapter 16 / ASCE 7-22`	Seismic — spring isolation horizontal restraint design
`ACI 318-19 Appendix D`	Concrete anchor design — spring mount Hilti Kwik Bolt TZ anchors
`AACE International RP 18R-97`	Cost Estimate Classification — Class 2 estimate basis for this EDP

3. Equipment Specification Summary

Detailed equipment specifications are in CBT-PRE-TDS-003 Rev 1 Section 6. This EDP section cross-references and adds ASI fabrication-specific requirements not in the TDS.

3.1 Primary Shredder — ASI Fabrication Requirements

Requirement	Specification	Verification
Inertia base concrete pour	Class 4000; poly fiber-reinforced 1.5 lb/yd³; #5 rebar 8-in. O.C.; 28-day cure minimum before FAT load test	Concrete test cylinders — 3× per pour; 28-day strength report submitted to Carbotura Engineering before FAT
Spring mount installation torque	Leveling bolt torque per Kinetics/Mason IOM; all 8 mounts within ±5% of target deflection at operating weight	Deflection measurement report at full weight — ASI PE sign-off
Skid paint / corrosion protection	SSPC-SP6 surface prep; 2-coat epoxy primer + polyurethane topcoat; minimum 6 mil DFT total	Wet film gauge measurements; holiday test per NACE SP0188
ASI-PWR-480-3PH-60A installation	Factory-installed on skid junction box; hi-pot test 1,000V DC per UL 50E before shipment	Hi-pot test certificate submitted with Unitized Warranty Passport
Nameplates	Stainless steel, laser-engraved; must include: Serial Number, Carbotura tag number, OEM model, rated kW, voltage, date of FAT completion	Visual inspection at FAT; photograph archived in Unitized Warranty Passport

4. Motor Schedule

Tag	Service	kW (P50/Peak)	Voltage	Enclosure	VFD	Service Factor
SHRD-TPS-001M	Tire Pre-Shredder	90–132 / 150	480V / 3Φ / 60Hz	TEFC	Yes	1.15
SHRD-SHR-001M	Primary Shredder #1 (hydraulic)	290 / 380	480V / 3Φ / 60Hz	TEFC	Via hydraulic	1.15
SHRD-SHR-002M	Primary Shredder #2 (hydraulic)	290 / 380	480V / 3Φ / 60Hz	TEFC	Via hydraulic	1.15
SHRD-HMR-001M	Hammermill #1	265 / 330	480V / 3Φ / 60Hz	TEFC	Soft-start	1.25
SHRD-HMR-002M	Hammermill #2	265 / 330	480V / 3Φ / 60Hz	TEFC	Soft-start	1.25
SHRD-APZ-001M	VRM Ash Pulverizer #1	185 / 235	480V / 3Φ / 60Hz	XPFC (Class II Div 1)	Yes	1.15
SHRD-APZ-002M	VRM Ash Pulverizer #2	185 / 235	480V / 3Φ / 60Hz	XPFC (Class II Div 1)	Yes	1.15
SHRD-MXR-001M	Rotational Mixer #1	115 / 155	480V / 3Φ / 60Hz	TEFC	Yes	1.15
SHRD-LWF-001/002M	Loss-in-Weight Feeders (2 active)	7.5 each / 11	480V / 3Φ / 60Hz	TEFC	Yes	1.15
SHRD-CV-xxx-M	Conveyors (7 total)	5–30 each	480V / 3Φ / 60Hz	TEFC	Yes (variable)	1.15

All motors: NEMA Premium Efficiency (IE3 equivalent); frame-agnostic with dimensional envelope specified; VFD-compatible winding insulation per NEMA MG1 Part 31 where VFD is specified. Hammermill motors: high-inertia soft-start; confirm WK² (flywheel effect) with OEM before procurement.

5. Instrument List (Key Items)

Tag (ISA 5.1)	Service	Type	Output	Zone
FIT-SHRD-001	Feedstock belt scale — Trough 1 discharge	Belt weigh feeder	4–20 mA TPH → AFR SCADA	General
AT-SHRD-APZ-001	LEL analyser — APZ Zone Z-03	Catalytic combustion LEL	4–20 mA 0–100% LEL → SCADA; 25% alarm, 40% trip	Class II Div 1
AT-SHRD-APZ-002	Residual O₂ analyser — APZ Zone Z-03	Electrochemical O₂	4–20 mA 0–25% O₂ → SCADA; >2% vol → APZ e-stop	Class II Div 1
VT-SHRD-SHR-001	Vibration — SHR-001 bearing housing	Wilcoxon 797 triaxial accelerometer	4–20 mA 0–1g RMS; alarm 4mm/s, trip 7.1mm/s	General
VT-SHRD-HMR-001	Vibration — HMR-001 bearing housing	Wilcoxon 797 triaxial accelerometer	4–20 mA 0–1g RMS; alarm 4mm/s, trip 7.1mm/s	General
LT-SHRD-ASL-001	Ash silo level — Stream A silo	Continuous radar level transmitter	4–20 mA 0–100% → SCADA; HIGH 80%, LOW 20%, LOW-LOW 10%	Class II Div 2
LT-SHRD-RFB-001	Regenesis Feed Bin level	Continuous ultrasonic level	4–20 mA; HIGH/LOW discrete alarms via ASI-DAT-MOD-TCP	General
PT-SHRD-N2-001	N₂ supply pressure — Z-03 inerting header	Pressure transmitter	4–20 mA 0–10 bar; SIL 1 interlock: <5.5 bar → APZ start permissive BLOCK	Class II Div 1
AT-SHRD-SHR-001	CO monitor — Primary Shredder enclosure	Electrochemical CO	4–20 mA 0–500 ppm; 25 ppm alarm, 100 ppm trip → enclosure CO purge	General

6. ASI Factory Acceptance Test (FAT) Plan

Mandatory FAT — Before Any Module Ships

No Shredder Train module may be shipped without a completed FAT signed by the ASI PE and Carbotura Engineering Lead. The Unitized Warranty Passport is issued only after FAT sign-off. All FAT documentation is archived in the Unitized Warranty Passport and in CBT document control.

FAT Hold Point	Description	Acceptance Criteria	Witness
HP-1	Material certification review — steel, concrete, gaskets, spring mounts	All materials certify to specified ASTM/ASME standards; concrete 28-day strength ≥4,000 psi	Carbotura Engineering Lead
HP-2	Dimensional inspection — skid envelope, nozzle schedule, anchor bolt pattern, nameplate	All dimensions within ±1/8 in. of drawing; nameplate present and legible; anchor pattern per PE-stamped drawing	Carbotura Engineering Lead
HP-3	Spring isolation — static load test and deflection measurement	All 8 mounts deflect within ±10% of calculated value at operating weight; leveling within ±0.005 in./ft	Carbotura Engineering Lead + ASI PE
HP-4	Electrical — hi-pot test, continuity, polarity, E-stop functional test	Hi-pot 1,000V DC on all ASI-PWR-480-3PH connections; all E-stop pull cords interrupt drive command within 200 ms; no continuity faults	Carbotura Controls Engineer
HP-5	Modbus TCP/IP — loop-check all I/O against SCADA tag list	100% of I/O points confirmed; AFR control loop response ≤20 ms; watchdog timeout confirmed	Carbotura Controls Engineer + ASI SCADA Team
HP-6	Dynamic run test — shredder + spring isolation vibration at rated load	fn <1 Hz (shredder); isolation efficiency ≥93% at 2 Hz; floor transmitted force ≤7% at 2 Hz; noise ≤85 dB(A) at 3 ft	Carbotura Engineering Lead + ASI PE (third-party acoustic engineer for dB measurement)
HP-7	APS duct flanges — smoke pressurization leak test	No visible smoke leak at any ASI-APS-FLG joint at –3.0 in. WC; VAV valve 0–100% stroke confirmed; flow element calibration certificate present	Carbotura APS Engineer
HP-8	Loss-in-weight feeder calibration	All 4 feeders within ±0.5% of setpoint across operating range; calibration certificate per OEM procedure	Carbotura Controls Engineer
HP-9	N₂ inerting SIL 1 interlock functional test	Low N₂ pressure (<5.5 bar) confirmed to block APZ start permissive within 2 seconds; O₂ analyser response tested with certified gas standard	Carbotura Safety Lead + ASI PE
FAT CLOSE	Unitized Warranty Passport package assembly and sign-off	All HP-1 through HP-9 documentation complete; all deficiencies resolved; ASI PE and Carbotura Engineering Lead signatures on FAT certificate	ASI PE + Carbotura Engineering Lead + Chairman (Allen Witters) if requested

7. Vendor Selection Matrix

Equipment	Preferred Vendors	OEM Guarantee	Lead Time	Selection Criteria Weight
Primary Shredder	Vecoplan VEZ 3200 / Lindner Polaris 2800 / SSI PRI-MAX PR4400	Yes — all three	26–32 weeks	Technical compliance 40%, OEM guarantee 20%, lead time 20%, support network 20%
Hammermill	Stedman Grand Slam / Metso Lindemann LIS	Yes — both	20–26 weeks	Same as shredder weighting
VRM Ash Pulverizer	Pfeiffer MPS 2000 / Loesche LM 15.2	Yes — both	32–40 weeks (critical path)	Grindability test result is deciding factor; test before final OEM selection
Rotational Mixer	Readco Kurimoto / BHS-Sonthofen DKXC	Readco: No / BHS: Yes	18–24 weeks	CV <5% FAT guarantee required; BHS preferred if budget permits
Magnetic Ferrous Separators (4×)	Eriez (US supply) / Bunting Magnetics (US) / Goudsmit (European)	Yes — all three	8–14 weeks	Short lead time; US service network preferred; Stage 2 needs high-intensity RE magnet
Loss-in-Weight Feeders	Schenck Process MULTICOR K / Coperion K-Tron K2-ML-D5	Yes — both	14–18 weeks	±0.5% accuracy guarantee required; both qualify

8. Warranty Requirements

Equipment	Required Warranty Period	Coverage Scope	Response Time (Criticality A)
Primary Shredders (2×)	24 months from Mechanical Completion	Cutter assembly, hydraulic drive, rotor, bearings, enclosure	24 hr notification response; 72 hr on-site
Hammermills (2×)	24 months	Hammers, grates, screens (manufacturing defects — not wear consumables), drive	24 hr / 72 hr on-site
VRM Ash Pulverizers (2×)	24 months	Rollers, grinding table, classifier, drive (excludes wear rate — separately modeled)	48 hr / 96 hr on-site
Rotational Mixer (1×)	18 months	Drum, paddles, drive, end seals	48 hr / 96 hr on-site
Spring Isolation Systems (all)	36 months from Mechanical Completion	Spring fatigue, weld integrity, leveling mechanism — extends module warranty by 12 months	Per ASI service agreement
All ASI-DAT-MOD-TCP-M12 modules	24 months	Hardware, gateway, M12 connectors, factory configuration	Remote support 4 hr; on-site 72 hr

Unitized Warranty Passport — Required Contents

The Unitized Warranty Passport issued by the ASI upon FAT completion must contain: (1) FAT completion certificate with all HP-1 through HP-9 results; (2) All material certification documents; (3) Concrete inertia base test cylinder reports; (4) Spring isolation deflection measurement report with ASI PE signature; (5) Electrical hi-pot test certificates; (6) Modbus I/O loop-check report; (7) APS duct flange leak test reports; (8) Feeder calibration certificates; (9) SIL 1 interlock test report; (10) Acoustic measurement report; (11) OEM warranty certificates (all equipment); (12) All ASI-issued serial numbers per Section 1.