Pregenesis Protocol — Master Operations Procedure
Facility-level startup, steady-state operations, mode transitions, abnormal operations, and shutdown for the Pregenesis Integrated Manufacturing Building (PIMB).
| Document Number | CBT-PRE-OPS-001 |
| Revision | Rev 1 — April 2026 |
| Status | WORKING DOCUMENT — Pre-Release Engineering Development |
| Parent TDS | CBT-PRE-TDS-001 Rev 2 |
| Governing ECNs | CBT-PRE-OER-AMD-001 Rev 1 · ECN-002 · ECN-003 · ECN-004 |
| Governing ARMs | ARM-2026-001 · ARM-2026-002 |
| Child Procedures | CBT-PRE-OPS-002 (Dumping Floor) · CBT-PRE-OPS-003 (Shredder Train) · CBT-PRE-OPS-004 (T2 Processing) |
| ISC | ISC-2 Confidential |
1. Purpose & Scope
This procedure is the master operations reference for the Pregenesis Protocol. It covers facility-level startup, steady-state operations, mode transitions, abnormal operations, and shutdown for the complete Pregenesis Integrated Manufacturing Building (PIMB).
| Modules covered | All Pregenesis modules — 0A, 0B, 0C, 0D, T2 (T2-ITD), Shredder Train (1–7), PRE-LFB-001, PRE-EVP-001, APS |
| Operating boundary | Site truck arrival gate (upstream) to ASI-RFH-FLG at PIMB–RMB shared wall (downstream) |
| Intake window | 12-hour daily delivery window (schedule set by Facility Manager) |
| Nameplate throughput | 1,000 TPD as-received |
| Canonical baseline | 400 TPD |
2. MCR Operating Modes
| Mode | EAF | Description | Revenue Baseline |
|---|---|---|---|
| Baseline MCR Mode | 0.00 |
No Enhancement Admix. Shredder Train operates without SHRD-APZ, SHRD-EAS, SHRD-LWF. Recyclotron MCR fully functional. | RevCon 3 baseline — financially modeled basis |
| Enhanced MCR Mode | 0.05–0.35 (target 0.25) |
Enhancement Admix active. All enhancement equipment online. Higher OmniCrude™ Carbon Phase yield. | Above RevCon 3 baseline |
3. Pre-Operation Checklist — Full Facility
| Check | Requirement |
|---|---|
| APS | Confirm APS at setpoint — negative pressure throughout PIMB before any conveyor or shredder starts |
| LOTO | All LOTO tags cleared and removed. Maintenance personnel signed off. |
| SCADA | All Pregenesis PLCs GREEN. SHRD-RFB level sensors reading. Regenesis SCADA demand signal active. |
| NXS-Z1-ELEC | Zero-E PowerBlock online and confirmed supplying PIMB Zone Bus |
| NXS-Z2-FLUID | WHSG thermal confirmed available for T2-ITD and PRE-EVP-001 |
| NXS-Z3-GAS | N&sub2; supply confirmed at operating pressure |
| PRE-EVP-001 | Confirm one evaporator unit on duty, one on standby (2:facility redundant pair) |
| T2-ITD | Confirm steam supply from NXS-Z2. T2-ITD-001 (duty) and T2-ITD-002 (standby) status. |
| PRE-LFB-001 | Liquifact collection manifold clear. Buffer level in normal range. |
| Vehicle manifest system | SCADA vehicle routing active. Lane assignments programmed for intake window. |
| Enhancement Admix (Enhanced MCR Mode) | SHRD-EAS silo level above LOW alarm. If unavailable, operate at Baseline MCR Mode. |
4. Facility Startup Sequence
| Step | System | Action | Confirm Before Advancing |
|---|---|---|---|
| 1 | APS | Start APS fans. Confirm negative pressure at setpoint throughout PIMB. | APS pressure confirmed at all zones |
| 2 | PRE-EVP-001 | Start duty Liquifact Evaporator. Confirm steam supply from NXS-Z2. | EVP-001 at operating temp |
| 3 | T2-ITD | Start duty T2-ITD. Confirm steam supply from NXS-Z2. Allow warm-up per OPS-004. | T2-ITD at operating temp |
| 4 | Shredder Train | Start per CBT-PRE-OPS-003 §3 (downstream-first rule within train). | SHRD-RFB level sensors GREEN; all PLCs GREEN |
| 5 | Trough 2 | Start T2 walking floor at minimum speed. | T2 feed confirmed routing to T2-ITD intake |
| 6 | Trough 1 | Start walking floor at minimum speed. | Shredder Train confirmed feed-ready |
| 7 | TISAB | Open TISAB for truck intake. Activate RFID and weighbridge systems. | SCADA vehicle routing active |
| 8 | Operations | Confirm all systems at setpoint. Authorize first truck entry. | All PLCs GREEN; Regenesis demand signal active |
5. Normal Operating Procedures
5.1 Throughput Control
Pregenesis throughput is set by Regenesis demand. The SCADA Regenesis demand signal drives walking floor speed at Troughs 1 and 2. The operator does not set throughput manually except during startup and shutdown ramps.
5.2 Trough Level Management
5.3 Vehicle Routing — SCADA Manifest Flags
| Manifest Flag | Bay Routing | Operator Action |
|---|---|---|
SEMI-ENDDUMP | Bridge bay — Trough 1 or 2 per manifest | None — SCADA automated |
SEMI-WALKFLOOR | Bridge bay — Trough 1 | None — SCADA automated |
COMPRESSION | Head-end bay — Trough 1 | None — SCADA automated |
DUMP-TRUCK | Head-end bay — Trough 1 | None — SCADA automated |
TANKER-LIQUID | Lane D → Module 0D | Operator confirms manifold connection |
5.4 Liquifact System
PRE-LFB-001 collects free liquids from all Pregenesis module drip pans, wastewater, and T2-ITD condensates continuously. PRE-EVP-001 (duty unit) evaporates to distillate water and solids concentrate. Distillate routes to REG-WHSG-001 feedwater via NXS-Z2-FLUID. Solids concentrate routing: D-17 open.
Monitor PRE-LFB-001 buffer level. If level approaches HIGH alarm, confirm duty PRE-EVP-001 is operating normally. Switch to standby EVP unit if duty unit faults.
5.5 EAF Mode Management
Key rule: Transition from Enhanced to Baseline MCR Mode is immediate on Enhancement Admix supply loss. No pause in Regenesis feed. Set EAF = 0.00 in SCADA and continue.
6. Abnormal Operations
6.1 APS Pressure Loss
| Severity | Condition | Response |
|---|---|---|
| Alarm | APS pressure rises above –0.01 in. WC | Alert operator. Investigate APS fan status. Check for open enclosure door. |
| Trip | APS pressure positive | SCADA auto-trip: stop all conveyors and shredders. Close TISAB. Investigate before restart. |
6.2 Shredder Train Fault
Refer to CBT-PRE-OPS-003 §6 for shredder-specific abnormal procedures. Master OPS action: if SHRD-RFB level drops to LOW during Shredder Train fault, notify Regenesis SCADA — Regenesis will hold at current feed rate until RFB level recovers.
6.3 T2-ITD Fault
Refer to CBT-PRE-OPS-004 §6. If T2-ITD-001 (duty) faults, switch to T2-ITD-002 (standby). NXS-Z2 steam supply switches automatically. If both units fault, continue Baseline MCR Mode without Enhancement Admix (T2 output is the Enhancement Admix source).
6.4 PRE-EVP-001 Fault
Switch to standby EVP unit. SCADA switches NXS-Z2 steam supply automatically. If both EVP units fault, PRE-LFB-001 buffer provides temporary surge capacity. Monitor buffer level. Alert Regenesis — WHSG feedwater supply will deplete within buffer hold time (D-23 open — hold time TBD).
6.5 Truck Manifest Mismatch
If SCADA detects vehicle type inconsistency (physical type ≠ manifest flag), hold truck in TISAB airlock. Operator resolves manifest before routing.
7. RevCon Operating Modes
RevCon Mode is set by Regenesis SCADA based on OmniCrude™ RC0 output quality and downstream processing status. Pregenesis follows Regenesis demand.
Governing: ARM-2026-001.
8. Shutdown Procedures
8.1 Planned Shutdown
| Step | Action |
|---|---|
| 1 | Notify Regenesis Operations — Pregenesis feed reducing to zero |
| 2 | Close TISAB — no new truck intake |
| 3 | Run out Trough 1 and Trough 2 to EMPTY — walking floors to full speed |
| 4 | Run out Shredder Train to EMPTY per OPS-003 §7 |
| 5 | Run out T2-ITD to EMPTY per OPS-004 §7 |
| 6 | Run out SHRD-RFB to EMPTY |
| 7 | Confirm ASI-RFH-FLG flow = 0 |
| 8 | Stop all conveyors and shredders per downstream-first rule (reverse of startup) |
| 9 | Leave APS running until PIMB is confirmed clear |
| 10 | Stop PRE-EVP-001 after PRE-LFB-001 buffer is emptied |
| 11 | APS shutdown — confirm all enclosures sealed before shutdown |
8.2 Emergency Shutdown
9. Key Performance Indicators
Key metrics include: TPD delivered to RFH, APS pressure, TISAB cycle time, EAF accuracy (Enhanced Mode), T2-ITD outlet moisture, PRE-LFB-001 level, PRE-EVP-001 distillate rate.
ARM-2026-002 Incorporated | T2-PDR → T2-ITD | EAF Terminology | ASI-RFH-FLG | RevCon 3 Baseline