Pregenesis Protocol — Operational Procedure
Feedstock Ingest, Trough Feed System
& Exit Airlock Scale Building
Modules 0A (TISAB), 0B (Feedstock Ingest & Troughs), 0C (EASB), 0D (Liquid Biosludge Station) — Complete feedstock intake & liquid receiving operations
Document Control
| Document Number | CBT-PRE-OPS-002 |
| Revision | Rev 1 — April 2026 |
| Status | WORKING DOCUMENT — Pre-Release Engineering Development |
| Parent Protocol | CBT-PRE-OPS-001 (Master Operational Protocol) |
| Related Documents | CBT-PRE-TDS-002 (technical basis) · CBT-PRE-OPS-003 (downstream Shredder Train) · CBT-PRE-OPS-004 (Trough 2 Processing) |
| Chairman | Allen Witters |
Manufacturing Classification Notice
All material received and handled within the boundary of this protocol is classified as Manufacturing Feedstock — an input material for Carbotura Advanced Circular Manufacturing. No waste treatment, storage, or disposal activities are defined or implied.Table of Contents
- Purpose & Scope
- Definitions
- Pre-Operation Checklist
- Truck Routing Protocol
- Airlock Door Interlock State Machine
- Rear Discharge Operations
- Trough 1 Operations — Manufacturing Feedstock & Tires
- Trough 2 Operations — Sludge & Ash
- EASB Exit Protocol
- Negative Pressure Management
- Li-Battery & Energetic Material Protocol
- Startup Sequence
- Shutdown Sequence
- Emergency Procedures
- Performance KPIs
1. Purpose & Scope
This protocol governs all operational procedures for the Pregenesis feedstock intake, receiving, and trough feed system — from truck arrival at TISAB through Manufacturing Feedstock delivery to the Shredder Train (CBT-PRE-OPS-003) and Trough 2 Processing (CBT-PRE-OPS-004). It covers Modules 0A (TISAB), 0B (Feedstock Ingest and Troughs), 0C (EASB), and 0D (Liquid Biosludge Delivery Station). Module 0D (ECN-003) receives liquid biosludge tankers via Lane D and routes liquid feedstock to Trough 2 Processing.
| Boundary | Description |
|---|---|
| Upstream | TISAB entry gate (truck arrival from public road) |
| Downstream (Trough 1) | Trough 1 lift conveyor discharge to Shredder Train — governed by CBT-PRE-OPS-003 |
| Downstream (Trough 2) | Trough 2 walking floor discharge to T2 Processing — governed by CBT-PRE-OPS-004 |
| Module 0D (Lane D) | Liquid biosludge tanker manifold connection to LBS-MNF-001 — routes to Trough 2 T2 Processing liquid inlet (ECN-003) |
2. Definitions
| Term | Definition |
|---|---|
| TISAB | Truck Intake and Scale Airlock Building — Module 0A. Entry pressure boundary and weighing station. |
| EASB | Exit Airlock Scale Building — Module 0C. Exit pressure boundary and tare weight confirmation station. |
| Airlock Sequence | Controlled door interlock cycle that maintains negative pressure boundary during truck transit. |
| Airlock Hold | Dwell period within the airlock where pressure equalization occurs, weight is captured, and load acceptance is confirmed. |
| Drawbridge | Hydraulically actuated bridge section over each trough that raises 45–70° to allow rear discharge cycle. |
| Walking Floor | Reciprocating slat conveyor at trough bottom. Moves Manufacturing Feedstock toward discharge at SCADA-controlled rate. |
| Tare Reconciliation | SCADA comparison of TISAB gross weight to EASB tare weight to confirm net payload delivered. |
| Quarantine Bay QA-01 | Reinforced concrete quarantine pit with water deluge for isolation of energetic or thermal hazard materials. |
| Manufacturing Feedstock | All input material received at the Pregenesis Feedstock Ingest. Processed as manufacturing input under Carbotura ACM operations. |
| Module 0D | Liquid Biosludge Delivery Station — ECN-003 addition. Receives liquid biosludge tankers (TANKER-LIQUID manifest) via Lane D. LBS-MNF-001 manifold; LBS-PMP-001/002 progressive cavity pumps; routes to T2 Processing liquid inlet. |
| Head-End Opening | 12 ft W × 6 ft H floor-grade opening at the entry end of each trough. Used by compression trucks (COMPRESSION manifest) for direct horizontal ejection. Bridge stays DOWN during head-end discharge. |
3. Pre-Operation Checklist
Mandatory First Step
Do not authorize truck intake or start any equipment until APS is confirmed running and negative pressure is confirmed in the Feedstock Ingest zone (–0.05 to –0.10 in. WC). This is non-negotiable.Pre-Operation Checklist — All items must be confirmed before authorizing intake
APS running and negative pressure confirmed (–0.05 to –0.10 in. WC in Feedstock Ingest)
MANDATORY FIRST — do not proceed if failed
TISAB/EASB door controls enabled — both Lane A and Lane B
All 4 bridge hydraulic power units pressure confirmed on SCADA
All drawbridges DOWN and latched — confirm via position sensors (Trough 1A, 1B, 2A, 2B)
Walking floor systems on STANDBY — Trough 1 and Trough 2
Lift conveyors on STANDBY — Trough 1 lift conveyor
Leachate sump pump on AUTO — Trough 2 sump pump
Magnetic head pulley operational on lift conveyor — confirm running prior to conveyor start
Thermal detection camera active (Li-battery detection at TISAB approach)
MANDATORY — do not accept loads without active thermal screening
Bay assignment system and LED signage active — test bay assignment display
SCADA truck routing system active — manifest loading confirmed
Ferrous collection bins FCB-001/002 below HIGH alarm — empty if near HIGH
4. Truck Routing Protocol
4.1 Vehicle Type Manifest System — SCADA Bay Assignment
Manifest Flag Controls All Routing
Every truck entering TISAB is identified by RFID/SCADA manifest flag at lane entry. Bay assignment, bridge state, and discharge method are determined by vehicle type — not material type alone. Operator may NOT override vehicle type routing without Shift Supervisor credential and SCADA reason code.| Vehicle Type | Manifest Flag | Discharge Method | Bay / Bridge State |
|---|---|---|---|
| 53' Semi + end-dump trailer | SEMI-ENDDUMP | Trailer body raise — gravity rear gate discharge | Trough tipping bay — bridge RAISES |
| 53' Semi + live walking floor trailer | SEMI-WALKFLOOR | Hydraulic walking floor — controlled rear discharge | Trough tipping bay — bridge DOWN |
| Compression truck (rear/side loader) | COMPRESSION | Packing blade — horizontal ejection at floor grade directly into trough head-end opening | Trough head-end opening bay — bridge stays DOWN. Bridge raise is interlocked BLOCKED while head-end bay is occupied. |
| Standard dump truck | DUMP-TRUCK | Own body raise — gravity rear gate discharge | Head-end bay (shorter trucks) or tipping bay — SCADA assigns based on truck length |
| Roll-off truck | ROLLOFF | Container tilt — gravity rear gate discharge | Head-end bay |
| Liquid biosludge tanker | TANKER-LIQUID | Gravity drain or pump via tri-clamp manifold — does NOT tip into trough | Module 0D station — Lane D only. Does NOT enter trough floor area. See Section 4.3 and Module 0D procedure below. |
| Unclassified / manifest discrepancy | UNCLASSIFIED | Hold — no discharge authorized | TISAB hold bay — Shift Supervisor review required before any door opens |
4.2 Normal Intake Sequence
Truck arrives at facility gate — transponder or RFID reads manifest. Bay assignment pre-loaded.
Traffic control assigns Lane A or Lane B. Entry door status check: entry door OPEN, exit door CLOSED and SEALED.
Truck advances onto scale pit — entry door closes and seals behind truck.
AIRLOCK HOLD: 15-second pressure equalization cycle. TISAB fans balance to –0.02 to –0.05 in. WC relative to outside. Do not open exit door until equalization complete.
Gross weight measured ±20 lb, tare subtracted, net payload calculated and logged to SCADA.
Load acceptance check: manifest match confirmed, weight within range, no prohibited materials flag.
Exit door opens — truck advances onto Feedstock Ingest. Exit door closes behind truck — lane reset initiated.
SCADA displays bay assignment on LED signage. Truck drives to assigned bay and tips load.
Empty truck drives toward EASB for exit via Section 9 protocol.
4.3 Compression Truck — Head-End Opening Discharge (COMPRESSION manifest)
Compression Truck Design Principle — ECN-003
Compression trucks discharge directly into the trough via the floor-level head-end opening. The hydraulic drawbridge REMAINS IN THE DOWN POSITION at all times. No bridge raise. No FEL. No intermediate transfer. The packing blade ejects material horizontally into the trough at floor grade.| Parameter | Value |
|---|---|
| Head-end opening width | 12 ft (full trough width) |
| Head-end opening height | 6 ft clear minimum |
| Opening sill elevation | Floor grade (0 in.) — no raised lip |
| Wheel stop distance | 24 in. from opening frame edge |
| Bridge state | DOWN — bridge raise BLOCKED while head-end bay is occupied (wheel stop + laser guide sensors DUMP-CHK-HE-001/002) |
| Impact wall | AR400 lined, bolt-on replaceable, at rear of head-end opening |
| APS capture | DUMP-APS-HE-001/002 dedicated capture hoods — 1,200 CFM normal / 2,000 CFM peak during discharge events |
SCADA confirms
COMPRESSION manifest flag. Head-end bay assignment issued. Bridge raise interlock BLOCKED for head-end bay lane.Truck backs to trough head-end opening. Laser guide system (DUMP-LGS-HE-001) provides alignment cues on LED display in Feedstock Ingest.
Confirm wheel stop engaged (DUMP-WS-HE-001 sensor ACTIVE). SCADA must confirm wheel stop before discharge is authorized. Bridge raise remains hard-locked.
APS head-end capture hood DUMP-APS-HE-001/002 confirms capture flow at setpoint before discharge authorized. Do not authorize discharge without confirmed APS capture.
Operator signals driver (intercom or radio). Driver activates packing blade ejection cycle. Material ejects horizontally at floor grade into trough. Operator monitors via CCTV DUMP-CAM-HE-001.
Discharge complete — driver closes rear door. Truck drives forward and proceeds toward EASB for tare weighing per Section 9.
Wheel stop sensor confirms truck has cleared head-end bay. Bridge raise interlock releases. SCADA logs compression truck event: truck ID, weight, bay, discharge time.
4.4 Module 0D — Liquid Biosludge Delivery Station (TANKER-LIQUID manifest)
Module 0D — ECN-003 Addition
Liquid biosludge tankers are routed to the dedicated Module 0D Liquid Biosludge Delivery Station via Lane D. They do NOT enter the trough floor area at any time. Lane D bypasses the trough bays entirely and terminates at the LBS manifold connection point downstream of the troughs within the PIMB.| Parameter | Value |
|---|---|
| Module designation | Module 0D — Liquid Biosludge Delivery Station |
| Lane assignment | Lane D only (dedicated liquid tanker lane — bypasses trough bays) |
| Connection type | LBS-MNF-001 — 4-in. tri-clamp, 316L SS, 2 simultaneous connections |
| Transfer method | Gravity or LBS-PMP-001/002 progressive cavity pumps (duplex, 50% duty) |
| DS% routing | DS ≥8% → T2-DCN centrifuge inlet (Trough 2 decanters) | DS <8% → bypass centrifuge → T2-ITD Indirect Thermal Dryer (T2-ITD) surge tank |
| DS% analyzer | LBS-ANL-001 — OPEN OER Gate 2: technology selection pending (ECN-003-A02) |
| APS capture | LBS-VNT-001 — 800 CFM normal / 1,400 CFM peak (H₂S, NH₃, methane) |
| H₂S alarm | 5 ppm → halt transfer + increase APS | 15 ppm → E-STOP Module 0D |
SCADA confirms
TANKER-LIQUID manifest flag at TISAB entry. Lane D assignment issued. APS LBS-VNT-001 confirms capture flow at setpoint — do not authorize connection without confirmed APS capture.Truck proceeds via Lane D past trough bay area to Module 0D manifold station. Truck stops at designated connection point — wheel stop sensor LBS-WS-001 confirms position.
Operator connects tanker hose to LBS-MNF-001 tri-clamp fitting. Confirm all connections torqued and leak-free before opening tanker valve.
Confirm H₂S reading <1 ppm at LBS-ANL-GAS-001 before opening tanker valve. If H₂S ≥5 ppm: halt, increase APS, notify supervisor, investigate source before proceeding.
Open tanker valve. LBS-FIT-001 begins flow totalization. SCADA monitors DS%, flow rate, and H₂S continuously throughout transfer.
Transfer complete. Close tanker valve. Operator disconnects LBS-MNF-001 connection — operate LBS-WASH-001 wash station to flush manifold after disconnection.
SCADA logs tanker event: truck ID, volume transferred (m³), DS% reading, H₂S max, transfer duration. Truck proceeds to EASB for tare weighing per Section 9.
5. Airlock Door Interlock State Machine
State Machine Scope
The following 8-state machine (STATE 0 through STATE 7) governs all TISAB and EASB door operations. No door movement is permitted outside this state machine logic. This applies to both Lane A and Lane B independently.| State | Description | Entry Condition | Exit Condition | Action Permitted |
|---|---|---|---|---|
| STATE 0 | Both doors closed — standby | Default on power-up or lane reset | Raise request + all interlocks clear | None |
| STATE 1 | Entry door opening | All interlocks confirmed clear | Entry door fully open confirmed by sensor | Truck enters |
| STATE 2 | Truck entering — on scale | Entry door fully open | Truck confirmed on scale (axle sensors) | Hold — no door movement |
| STATE 3 | Entry door closing | Truck on scale confirmed | Door closed and sealed (seal sensor) | Weighing begins |
| STATE 4 | AIRLOCK HOLD | Entry door sealed | Pressure equalized + weight captured + acceptance confirmed | Weighing and pressure monitoring |
| STATE 5 | Exit door opening | Entry door sealed + load acceptance approved | Exit door fully open confirmed | Truck exits to Feedstock Ingest |
| STATE 6 | Truck exiting | Exit door fully open | Truck clear + dump body DOWN confirmed | Hold — no door movement |
| STATE 7 | Exit door closing — lane reset | Truck clear + body DOWN confirmed | Exit door closed and sealed | Prepare for next truck → STATE 0 |
6. Rear Discharge Operations
6.1 Drive-Over Drawbridge — Ingest Sequence
Drive-Over Operation
The drawbridge is the truck roadway spanning the trough. Trucks drive forward onto the bridge and stop directly over the trough — they do not tip alongside it. The entire bridge span then raises from the entrance-side pivot, exposing the trough below for rear-discharge dumping. No reversing required — drive-through operation.
Truck exits TISAB and advances forward into the Feedstock Ingest building. SCADA LED signage displays assigned lane and trough position.
Truck drives forward onto the drawbridge — the bridge is the structural roadway spanning the 16 ft trough. Wheel guide rails on both sides of the bridge prevent lateral drift. Truck continues until rear axle position sensor confirms correct stop position over trough.
Auto-chocks engage automatically on truck-stop confirmation. Chock engagement confirmed via sensor on both sides. Bridge raise is hard-interlocked until chock engagement confirmed. Chocks remain engaged through entire dump cycle.
Bridge interlock check (automatic, <2 seconds): (1) auto-chocks engaged confirmed, (2) adjacent bridge on same trough DOWN confirmed, (3) no personnel detected in trough zone below, (4) hydraulic pressure nominal, (5) APS negative pressure confirmed in trough zone.
APS extraction rate increases for affected trough zone — confirmed within 30 seconds of raise command before bridge movement begins.
Bridge raises — entrance-side pivot, full span rises as single unit to 45° nominal. Target <60 seconds full travel. Counterweight balances span — smooth hydraulic lift. Trough is now fully exposed below the raised bridge and truck trailer.
Truck raises dump body rearward — Manufacturing Feedstock discharges into exposed trough below. Bridge remains raised and chocks remain engaged throughout dump body raise and discharge cycle.
Dump body DOWN sensor must confirm body fully lowered and latched before bridge lower is permitted. Operator confirms visually. Bridge lower command issued.
Bridge lowers — returns to flush/drive-over position. Confirmed DOWN and latched by position sensor. Target <60 seconds. Bridge is now the truck roadway again.
Chocks release — confirmed by sensor. Truck drives forward off the bridge and toward EASB exit. Next truck may now advance onto bridge.
6.2 Bridge Safety Interlock State Machine
| State | Name | Entry Condition | Exit Condition |
|---|---|---|---|
| B0 | Bridge DOWN / Locked | Power-up default or bridge lower confirmed | Raise request + all interlocks clear |
| B1 | Interlock Check | Raise request received | All interlock conditions confirmed clear |
| B2 | Bridge Raising | All interlocks cleared | Bridge at full dump angle confirmed |
| B3 | Bridge UP / Dump Active | Bridge at 45° — trough exposed below | Dump body DOWN confirmed + lower request issued |
| B4 | Bridge Lowering | Lower request + body DOWN confirmed | Bridge DOWN and latched confirmed |
| B5 | FAULT / Locked | Any interlock violation or sensor fault | Supervisor reset + fault cleared + manual confirmation. LOTO required for access. |
Two-Bridge Operation Rule — No Override
Only ONE bridge per trough may be raised at any time. This rule has no override. Raising both bridges on the same trough simultaneously is a hard interlock — prohibited regardless of load conditions. Both troughs may be active simultaneously (e.g., Trough 1 Bridge A raising while Trough 2 Bridge B is lowering is permitted).6.3 Trough Selection and Lane Assignment Logic
Selection Principle
Trough assignment is determined by load manifest type at TISAB entry. SCADA routes each truck to the correct lane and trough automatically. Operator confirmation is required before rear discharge. Manual override by Shift Supervisor only — requires reason code entry in SCADA.
| Manifest Material Type | Assigned Trough | Assigned Lane | Override Permitted? |
|---|---|---|---|
| MSW — General Municipal Manufacturing Feedstock | Trough 1 | Lane A or B | No — hard routing |
| Tires / Tire-Derived Feedstock | Trough 1 | Lane A or B | No — hard routing |
| Bulky / C&D Manufacturing Feedstock | Trough 1 | Lane A or B | No — hard routing |
| WTE Bottom Ash (Stream A) | Trough 2 | Lane A or B | No — hard routing |
| Biosolids / Sludge / Dewatered Cake | Trough 2 | ||
| WTE Bottom Ash (wet quenched) | Trough 2 | Lane A or B | No — hard routing |
| Coal Ash — wet bottom ash | Trough 2 | Lane A or B | No — hard routing |
| Coal Mine Tailings (wet) | Trough 2 | Lane A or B | No — hard routing |
| Critical Materials and Minerals (CMM) — wet solids | Trough 2 | Lane A or B | No — hard routing |
| Dry Fly Ash (pneumatic delivery) | Direct to Admix Silos | N/A — dry intake | Supervisor authorization | Lane A or B | No — hard routing |
| Mixed Load — MSW + Ash | SCADA Decision | Lane A or B | Supervisor approval required |
| Unknown / Manifest Discrepancy | Quarantine Bay | Hold at TISAB | No — QA-01 hold required |
6.3.1 Lane Congestion Management
When the assigned trough lane is occupied (bridge raised or prior truck still clearing), SCADA holds the incoming truck at the TISAB exit door interlock. The alternate lane on the same trough may be offered if the material type is compatible. Both troughs may operate simultaneously — Lane A on Trough 1 and Lane B on Trough 2 is a normal concurrent configuration. SCADA displays queue status on the LED signage inside the Feedstock Ingest building.
6.3.2 Trough Maintenance Lockout Routing
When one trough is under LOTO for planned maintenance, SCADA automatically re-routes all compatible loads to the available trough. MSW and Tires always route to Trough 1 — if Trough 1 is locked out, receiving operations for MSW and Tires must suspend. Ash and Sludge loads may be re-routed to Trough 1 under Shift Supervisor approval with SCADA override code entry. Notify Dispatch to hold deliveries during extended trough lockout exceeding 4 hours.
6.4 Auto-Chock System — Operating Procedure
Safety Mandate
The auto-chock system is a life-safety device. No bridge raise is permitted under any circumstance without confirmed dual-side chock engagement. Manual override of the chock interlock requires Shift Supervisor physical key switch and SCADA reason code. LOTO is required for any access to the chock mechanism during maintenance.
6.4.1 Chock Engagement Sequence
Truck-stop sensor confirms rear axle in correct position over trough (SCADA tag: DUMP-TPS-001A/B). Audible tone sounds in building — truck driver must remain in cab.
Auto-chock extend command issues automatically. Both chock assemblies (driver side and passenger side) extend simultaneously. Engagement confirmed via dual proximity sensors (DUMP-CHK-001A/B). SCADA displays CHOCK ENGAGED on HMI and LED signage.
Dual-sensor confirmation required — both sides must confirm engagement within 5 seconds. If either sensor fails to confirm: chock extend command reissues once. If second attempt fails: fault alarm DUMP-CHK-FAULT-001, bridge raise hard-locked, Shift Supervisor notification. Do not attempt manual chock verification while truck is positioned over trough.
Rising trough curb extends automatically (DUMP-RCB-001/002/003/004). Curb plate rises 10 in. (254 mm) above finished slab at the trough lip — blocking any rollback of truck or load into the open trough. Curb raised position confirmed via DUMP-RCB-POS sensor within 3 seconds. If curb fails to confirm raised: bridge raise command is hard-blocked. Do not bypass curb interlock under any circumstance — this is a life-safety device.
SCADA bridge raise interlock clears on confirmed dual chock engagement AND confirmed curb raised position. Bridge raise may now proceed per Section 6.1.
6.4.2 Chock Hold During Rear Discharge Cycle
Chocks remain engaged and powered throughout the entire rear discharge cycle: bridge raising, bridge at full angle, dump body raising, material discharge, dump body lowering, and bridge lowering. Chock release is hard-interlocked until ALL of the following conditions are met simultaneously: (1) bridge fully DOWN confirmed (DUMP-HDB-POS-DOWN), (2) bridge latch engaged (DUMP-HDB-LATCH), (3) dump body DOWN confirmed (DUMP-BDY-DOWN-001). Any single condition not met: chocks remain engaged.
6.4.3 Curb Lower and Chock Release Sequence
Bridge fully lowered and latch confirmed. Dump body DOWN sensor confirmed. All three release conditions met — SCADA issues chock retract command.
Both chock assemblies retract. Retract confirmed via dual proximity sensors. SCADA displays CHOCK CLEAR on HMI and LED signage — audible tone (distinct from engagement tone).
Truck drive-clear confirmed by exit loop detector or forward motion sensor. Lane reset — next truck may advance.
6.4.4 Chock Fault and Manual Override
If a chock fails to retract after rear discharge (chock stuck engaged): truck remains held — do not attempt to drive out. Shift Supervisor enters SCADA override code and uses physical key switch at the HPU panel to command manual retract. If manual retract fails: LOTO chock mechanism, contact maintenance. Chock assembly accessible from the side of the bridge frame with bridge in fully lowered and latched position only.
6.5 Drawbridge Raise and Lower — Full Operating Procedure
6.5.1 Pre-Raise Checklist
HPU hydraulic pressure nominal — DUMP-HPU-001: 2,500–3,000 PSI operating range. Low-pressure alarm DUMP-HPU-LPA-001 must be clear.
Hydraulic fluid level confirmed — sight glass ≥75% full. No active fluid leak alarms.
Adjacent bridge on same trough confirmed DOWN and latched (hard interlock — SCADA prevents raise if adjacent bridge not confirmed down).
Personnel clear of trough zone — laser curtain / photo-eye array clear (DUMP-PEC-001). No entry to trough zone is permitted while bridge is raised or in motion.
APS negative pressure confirmed in Feedstock Ingest zone — DUMP-APS-DP-001: minimum −0.02 in. WC. APS rate increase pre-command acknowledged.
Auto-chocks engaged — dual confirmation per Section 6.4.1. Bridge raise is hard-locked until this confirmation is received.
6.5.2 Bridge Raise Sequence
SCADA issues APS rate-increase pre-command for affected trough zone. Confirm APS flow increase acknowledged within 30 seconds before proceeding.
Raise command issued — HPU solenoid opens. Bridge begins to rise from entrance-side hinge. Counterweight assists — hydraulic load is the counterbalanced remainder only.
Bridge travel monitored by encoder / angle sensor (DUMP-HDB-ANG-001). Rate of travel: 0–45° in <60 seconds. Controlled acceleration for first 5° and deceleration in final 5° to prevent load shock at end stops.
Bridge at 45° nominal — position sensor DUMP-HDB-POS-UP confirms. HPU solenoid shifts to hold (pressure maintained). Trough fully exposed below.
Truck driver may now raise dump body. Bridge holds position under hydraulic pressure lock. Do not lower bridge while dump body is raised.
6.5.3 Bridge Lower Sequence
Dump body DOWN sensor must confirm (DUMP-BDY-DOWN-001) before lower command is accepted. SCADA hard-blocks lower command until this sensor clears. Operator confirms visually from observation position.
Lower command issued — HPU solenoid opens return circuit. Counterweight assists controlled descent. Bridge returns from 45° to flush/drive-over position.
Controlled deceleration in final 5° of travel. Bridge lands on support pads — position sensor DUMP-HDB-POS-DOWN confirms. Latch engages automatically (DUMP-HDB-LATCH confirmed).
HPU solenoid closes. Hydraulic pressure releases to standby. Bridge is now the truck roadway — structurally capable of supporting next truck load.
Chock release sequence initiates per Section 6.4.3. Truck drives forward and exits. Lane resets for next truck.
6.5.4 Bridge Fault Conditions
| Fault Condition | Immediate Action | SCADA Alarm |
|---|---|---|
| Bridge fails to reach UP position in 90 seconds | Hold position — do not reverse. Call maintenance. Do not allow truck to drive out. | DUMP-HDB-TRAVEL-TIMEOUT |
| Hydraulic pressure loss during raise | Bridge holds position under gravity lock. Issue lower command — controlled descent by counterweight. If bridge does not descend: LOTO, call maintenance. | DUMP-HPU-LPA-001 |
| Bridge stuck in raised position | Stop all rear discharge operations. Do not allow access under raised bridge without LOTO and mechanical prop installed. Contact maintenance. | DUMP-HDB-STUCK-UP |
| Chock fails to release with bridge down | Supervisor key override at HPU panel. Manual retract command. If fails: LOTO — do not attempt to drive truck out. | DUMP-CHK-STUCK |
| Personnel detected in trough zone during raise | Bridge stops immediately — holds position. E-stop latches. Supervisor must confirm clear before reset. | DUMP-PEC-INTRUSION |
| Adjacent bridge raises while this bridge is up | Impossible — hard interlock. If alarm fires, indicates sensor failure. LOTO both bridges. Call maintenance. | DUMP-HDB-DUAL-UP |
7. Trough 1 Operations — Manufacturing Feedstock & Tires
7.1 Trough Level Response
| Level Condition | Action | Notification |
|---|---|---|
| HIGH (>80%) | Pause Trough 1 truck intake — hold new deliveries | Alert operations and dispatch |
| NORMAL (20–80%) | Normal operation | None required |
| LOW (<20%) | Increase walking floor speed — request additional truck routing | Alert dispatch |
| LOW-LOW (<5%) | Shredder Train notified of low feed — prepare for feed interruption | Alert OPS-003 operator immediately |
Tire Handling: Whole tires must be tipped at the designated tire bay only — the first 50 ft of Trough 1 (solid-plate bridge section). Crumb rubber and pre-shredded tire material require no special handling and may be tipped at any Trough 1 bay.
APS Rule: If APS capture is lost, rear discharge operations for Trough 1 must stop immediately. No atmospheric venting is permitted under any operating condition.
8. Trough 2 Operations — Sludge & Ash
8.1 NIR Moisture Routing Logic
| NIR Reading | Material Class | Primary Route | Process Path |
|---|---|---|---|
| <15% | Ash | Bypass dryer | Lumpbreaker → Ash Pulverizer |
| 15–30% | Ash | Dryer trim cycle | Lumpbreaker → Ash Pulverizer |
| >30% | Ash | Full dryer cycle | Lumpbreaker → Ash Pulverizer |
| <15% | Sludge | Flag anomalous — supervisor review | Ash Path (likely dried cake) |
| 15–60% | Sludge | Pre-dewatering → Dryer | Sludge Pulverizer |
| >60% | Sludge | Pre-dewatering MANDATORY | Sludge Pulverizer |
8.2 Leachate Management
| Condition | Action | Next Step |
|---|---|---|
| Normal level | Sump pump AUTO — no intervention | Log volume per shift |
| HIGH alarm | Reduce sludge intake rate — increase pump rate | Monitor until HIGH cleared |
| HIGH-HIGH alarm | Stop Trough 2 intake immediately | Supervisor notification — do not resume until sump capacity confirmed |
⚠ LOCKOUT / TAGOUT REQUIRED — Trough 2 Wash-Down
LOTO required on Trough 2 walking floor and all Trough 2 feed conveyors before any personnel entry into the trough area for wash-down or maintenance.
Confirm zero energy state on all drives before entry. All wash water to leachate collection tank — zero floor discharge.
Zero-discharge policy: no leachate, wash water, or centrate may be discharged to drain or ground under any condition.
9. EASB Exit Protocol
9.1 Normal Exit Sequence
Empty truck drives from Feedstock Ingest toward EASB. Traffic signal assigns Lane A or Lane B.
Entry door opens, truck advances onto EASB scale — entry door closes and seals. AIRLOCK HOLD: 15-second pressure equalization.
Tare weight measured ±20 lb and logged to SCADA.
SCADA tare reconciliation: EASB tare vs TISAB gross = net payload confirmed. Within ±5% = ACCEPT. Outside tolerance = FLAG for supervisor review.
Exit door opens — truck exits to public road. Exit door closes — lane reset. Load record closed with full timestamps.
9.2 Reconciliation Discrepancy Protocol
| Condition | SCADA Action | Operator Action |
|---|---|---|
| Within ±5% | ACCEPT — record closed automatically | None required |
| Outside ±5% (first occurrence) | FLAG — load record held open — supervisor alert | Investigate cause — document resolution |
| Scale drift suspected | Flag for calibration check | Remove scale from service pending calibration |
| Partial tip confirmed | Adjust delivered tonnage in manifest record | Document and notify dispatch |
10. Negative Pressure Management
10.1 Normal Pressure Setpoints
| Zone | Tag | Normal Range | Low Alarm | High Alarm |
|---|---|---|---|---|
| TISAB / EASB Airlock | DUMP-APS-DP-AIRLOCK | −0.02 to −0.05 in. WC | <−0.02 in. WC | >−0.05 in. WC |
| Feedstock Ingest — Trough Zone | DUMP-APS-DP-001 | −0.05 to −0.10 in. WC | <−0.05 in. WC | >−0.10 in. WC |
| Feedstock Ingest — Building | DUMP-APS-DP-002 | −0.03 to −0.07 in. WC | <−0.03 in. WC | >−0.10 in. WC |
| Trough 1 — Active Rear Discharge | DUMP-APS-DP-TR1 | −0.08 to −0.12 in. WC | <−0.06 in. WC (bridge raised) | — |
| Trough 2 — Active Rear Discharge | DUMP-APS-DP-TR2 | −0.08 to −0.12 in. WC | <−0.06 in. WC (bridge raised) | — |
10.2 Pressure Response Protocol
LOW PRESSURE ALARM (below setpoint): SCADA alerts operator. Verify APS fan running at commanded speed. Check for open doors, failed door seals, or damaged airlock. If pressure not restored within 2 minutes: suspend rear discharge on affected trough per Section 10.3.
PRESSURE LOSS DURING ACTIVE REAR DISCHARGE (bridge raised): Immediately lower bridge. Do not initiate new rear discharge cycles until pressure is restored and confirmed stable for >5 minutes. Log event in SCADA — mandatory.
HIGH PRESSURE ALARM (exceeds setpoint): Indicates APS over-extraction or recirculation failure. Reduce APS fan speed 10% increments until pressure returns to normal range. If above −0.10 in. WC persists: check APS recirculation damper position. Notify engineering if not resolved within 15 minutes.
10.3 Pressure Fault — Rear Discharge Suspension Procedure
Rear discharge operations for affected trough suspended until APS pressure restored and confirmed stable ≥5 minutes.
If bridge is raised: issue lower command immediately. Confirm bridge DOWN and latched before any personnel approach.
Notify Shift Supervisor. Log fault start time, trough number, pressure reading at fault, and APS fan status in SCADA event log.
Investigate: Check DUMP-APS-FAN-001 speed feedback, inlet filter differential pressure, duct integrity, and all door interlock sensors in the affected zone.
On pressure restoration: confirm stable ≥5 minutes before resuming. Resume requires Shift Supervisor authorization.
| Zone | Normal Setpoint | Alarm Low | Alarm High | Action if Out of Range |
|---|---|---|---|---|
| Feedstock Ingest (0B) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — adjust extraction rate |
| TISAB Airlock (0A) | –0.02 to –0.05 in. WC (during hold) | –0.01 in. WC | –0.10 in. WC | Hold truck — do not open exit door |
| EASB Airlock (0C) | –0.02 to –0.05 in. WC (during hold) | –0.01 in. WC | –0.10 in. WC | Hold truck — do not open exit door |
| Trough 1 (below floor) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — check Trough 1 APS damper |
| Trough 2 (below floor) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — check Trough 2 APS damper |
Pressure Fault During Rear Discharge — Stop Rear Discharge Immediately
If Feedstock Ingest or trough zone pressure rises above –0.03 in. WC while any bridge is raised: (1) SCADA auto-issues bridge lower command. (2) Operator confirms bridge lower — do not wait for auto-confirm. (3) Pause all rear discharge cycle in affected zone. (4) Investigate APS fault before resuming. Do not resume rear discharge operations until APS confirmation that negative pressure is restored to setpoint.11. Li-Battery & Energetic Material Protocol
11.1 Detection and Quarantine Sequence
Thermal camera triggers on object above 80°C — SCADA alert generated immediately.
Lift conveyor divert gate activates — material routed to Quarantine Bay QA-01. Lift conveyor pauses.
Rear discharge operations for Trough 1 suspended until QA-01 inspection complete.
QA-01 water deluge activates automatically on temperature confirmation above 120°C.
Operations supervisor notified immediately — quarantine log entry created.
⚠ QA-01 Entry Requirements — Strict Compliance
No personnel may enter QA-01 until: CO concentration <25 ppm (confirmed by calibrated meter) AND temperature <40°C.
LOTO required on water deluge system before personnel entry. Two-person minimum at all times in QA-01.
Full PPE including SCBA if CO or temperature cannot be confirmed prior to entry.
12. Startup Sequence — Modules 0A/0B/0C
12.1 Pre-Startup Checks
Confirm all LOTO tags cleared and removed. All maintenance personnel signed off LOTO log. No active PTWs open on Modules 0A/0B/0C.
APS system: verify fans running, verify negative pressure building in all zones per Section 10.1 setpoints. Do not open airlock doors until all zones confirm negative pressure.
TISAB and EASB: verify weighbridge zero calibration — perform zero span check. Verify door interlock sensors functional — cycle each door under manual control, confirm all position sensors respond correctly.
Feedstock Ingest: verify all bridge position sensors show DOWN and LATCHED. Verify auto-chock sensors show RETRACTED. Verify HPU pressure nominal on both Trough 1 and Trough 2 HPUs.
Trough 1: verify walking floor drive online and responding to SCADA speed command. Verify lift conveyor ready — no jam alarms. Verify Trough 1 level sensor reading.
Trough 2: verify walking floor drive online. Verify NIR moisture sensor calibration current — check last calibration date. Verify dewatering and dryer systems ready per OPS-004 startup checklist.
SCADA: confirm all DUMP- and TISAB- tagged points scanning normally. Acknowledge any standing alarms and resolve or document. Load today's truck schedule manifest into dispatch module.
12.2 System Startup Order
Start sequence must follow this order to maintain containment and interlock integrity: (1) APS system — fans, duct dampers, capture system ready; (2) Trough conveyors and downstream equipment (Shredder Train per OPS-003 startup); (3) Trough level management — confirm downstream has capacity before opening intake; (4) Feedstock Ingest building — bring HPUs online, confirm all interlock sensors healthy; (5) Airlock systems — bring TISAB and EASB door interlocks online; (6) Open facility gate to incoming trucks.
12.3 First-Truck Protocol
The first truck of each shift receives a manual walk-through by the Shift Supervisor before SCADA releases for automated operation. The Shift Supervisor physically confirms: bridge in correct position, chock system responsive, trough zone clear, and APS negative pressure audibly and visually confirmed (negative pressure indicator at building entry). Sign-off in SCADA — mandatory before releasing automated truck routing.
Startup Rule — APS First, Always
Step 1 is mandatory and non-negotiable. No other equipment may be started until APS is confirmed running and negative pressure is confirmed in the Feedstock Ingest zone.APS confirmed running and negative pressure confirmed (–0.05 to –0.10 in. WC). MANDATORY FIRST STEP — do not proceed if failed.
EASB door controls enabled — Lane A and Lane B.
Leachate sump pump set to AUTO.
Walking floors set to STANDBY — Trough 1 and Trough 2.
Lift conveyors set to STANDBY.
Trough 2 feed conveyors set to STANDBY.
Bridge hydraulic power units ON — pressure confirmed on SCADA.
Bridge controls enabled — all bridges confirmed DOWN and latched on position sensors.
Thermal detection camera confirmed active.
Feedstock Ingest LED bay assignment system active — test display cycle.
Module 0A/0B/0C READY: Notify TISAB to begin truck intake. Notify OPS-003 (Shredder Train) and OPS-004 (Trough 2 Processing).
13. Shutdown Sequence
13.1 Planned Shutdown — End of Shift / Day
Notify Dispatch: stop accepting new truck bookings for this intake window. Allow all trucks currently within the facility perimeter to complete their rear discharge cycle before proceeding.
Process all trucks in facility — confirm all bridges returned to DOWN and LATCHED, all chocks RETRACTED, all trucks cleared through EASB.
Walking floors: run Trough 1 and Trough 2 walking floors until trough level sensor reads below 20% — confirm downstream shredder train has consumed the queued material.
Close TISAB entry door — lock in closed position via SCADA. Close EASB exit door — lock in closed position. Building sealed for pressure maintenance overnight.
APS: maintain at reduced flow (30% fan speed minimum) — do not shut down APS while any residual Manufacturing Feedstock remains in troughs or on conveyors.
Complete shift log: total trucks received, total tonnage by trough, any events (bridge faults, chock faults, pressure alarms, rejections), and outstanding maintenance items. Sign off in SCADA.
13.2 Emergency Shutdown — Immediate
For immediate unplanned shutdown: press facility E-stop master (located at TISAB operator station and at Feedstock Ingest control panel). All bridge movements halt. All door interlocks hold current position. Chocks remain engaged if activated. APS remains running — do not shut down APS during emergency shutdown. Contact Shift Supervisor and follow Section 14 Emergency Procedures for the specific event type.
13.3 Extended Shutdown — Maintenance or Holiday
For shutdowns exceeding 24 hours: fully empty both troughs via walking floor and lift conveyor. Wash down trough walls per cleaning procedure CBT-PMI-DUMP-001. Lock all doors closed. Shut down APS fans after confirmed trough empty and clean. Apply LOTO to HPU main disconnect, walking floor drives, and lift conveyors. Notify maintenance for scheduled PMI items. Leave SCADA system in monitoring mode — do not power down SCADA during extended shutdown.
Shutdown Rule — APS Last, Always
The APS must remain running until all material has been cleared from the Feedstock Ingest building and all enclosures are sealed. Do not shut down APS while any trough, bridge, or conveyor is active.Notify dispatch: no new truck assignments. Allow in-transit trucks to complete their cycle.
Stop Trough 1 and Trough 2 walking floors after last truck completes rear discharge.
Allow lift conveyors to run until material clear — confirm empty by level sensor and visual.
Stop lift conveyors. Stop Trough 2 feed conveyors.
Lower all bridges — confirm DOWN and latched on all position sensors.
Bridge HPUs OFF after bridges confirmed down.
Leachate sump pump to MANUAL — confirm sump pumped down before shutdown.
Door controls disabled — all doors confirmed closed and sealed.
APS shutdown only after building fully sealed and all equipment stopped. Notify APS operator — coordinate APS shutdown timing.
13B. Fire Suppression System — Operating Procedures
All systems automatic — no manual activation required for initial response
The PIMB fire suppression system activates automatically on thermal camera trigger (monitor nozzles) or fusible link activation (wet pipe sprinklers). Operator actions are post-activation: personnel evacuation, SCADA acknowledgment, and notification. Do not attempt to manually suppress a trough fire before the automatic systems have activated.
13B.1 Thermal Camera — Monitor Nozzle Activation
Thermal camera DUMP-TIC-001 through -008 continuously monitors trough zones. Normal threshold monitoring is automatic — no operator action required.
On FIRE ALARM — TROUGH ZONE: SCADA sounds alarm. APS ramps to maximum extraction automatically. Bridge raise command is hard-blocked for the affected bay. Monitor nozzle DUMP-FPS-MON-xxx trains on heat source and oscillates across hot zone automatically.
Evacuate personnel from Feedstock Ingest immediately. Do not re-enter trough zone while suppression is active. Personnel exclusion zone: entire PIMB Feedstock Ingest floor.
Notify: Facility Safety Officer → ASI (Authorized Strategic Integrator) 24-hr line → Emergency services (911) if fire is not controlled within 5 minutes of suppression activation.
SCADA logs: alarm timestamp, camera ID, monitor nozzle activation, flow meter reading, APS extraction rate. Do not reset alarm without Safety Officer authorization.
13B.2 Wet Pipe Sprinkler Activation
On sprinkler activation: Evacuate entire PIMB immediately. Sprinkler activation indicates heat sufficient to fuse link — active fire condition confirmed. Contact emergency services (911) immediately.
Do not re-enter PIMB until fire department clears the building. SCADA E-stop all equipment on sprinkler flow switch signal.
After fire department clearance: inspect trough for structural damage before any restart. Contact Carbotura Engineering before resuming operations.
13B.3 Nitrogen Inerting Activation (Conveyors / VRM)
On N₂ inerting activation — conveyor or VRM enclosure: LOTO all affected equipment immediately. N₂ atmosphere is immediately lethal — do not open any access door on activated enclosure without confirmed O₂ level >19.5% via portable monitor.
N₂ activation logged to SCADA with timestamp and enclosure ID. Notify Shift Supervisor and Safety Officer.
Purge enclosure with forced ventilation before any maintenance access. Confirm O₂ level with calibrated monitor — minimum 19.5% before entry. Buddy system required.
13B.4 Li-Battery Fire — Special Protocol
Li-Battery Thermal Runaway — Do Not Use Dry Chemical or CO₂
Li-battery fires require continuous water application for cooling. Dry chemical and CO₂ suppress visible flame but do not cool the cell — re-ignition occurs. Apply water continuously until temperature is confirmed below 35°C.
If Li-battery thermal runaway confirmed in trough after discharge: do not attempt manual suppression. Monitor nozzle system applies water automatically. Evacuate Feedstock Ingest. Contact emergency services.
If Li-battery detected at TISAB entry (thermal camera alert before discharge): reject load immediately. Direct truck to quarantine bay QA-01. Activate water deluge at QA-01. Contact emergency services.
14. Emergency Procedures
Emergency Authority
Any operator may initiate an emergency stop. Only the Shift Supervisor may authorize restart after an emergency stop. All emergency events require SCADA logging with start time, event type, actions taken, and resolution time.
14.1 Fire or Smoke Detection — Feedstock Ingest
Activate building E-stop. Halt all bridge and conveyor movement. Do not lower a raised bridge into a fire — hold position.
Call facility emergency number. Evacuate all personnel from Feedstock Ingest building. Do not re-enter.
SCADA auto-triggers: (1) APS isolation dampers close to contain fire zone; (2) fixed suppression system activates per NFPA 13; (3) TISAB and EASB doors lock closed.
Notify fire department. Provide trough contents manifest — identify if tire or energetic material loads are involved. Do not resume operations without fire department clearance and engineering sign-off.
14.2 Truck Struck Bridge or Building Structure
Stop all operations in affected lane. Do not move bridge or chocks until structural inspection is complete.
Secure truck in place — do not allow driver to move vehicle. Call emergency services if injury suspected. Lock out affected lane HPU.
Notify Shift Supervisor and engineering. Structural inspection required before any bridge operation resumes. If bridge is raised at time of impact: do not lower until structural clearance given.
Incident report in SCADA. Opposite lane may continue operating if structurally unaffected and Shift Supervisor confirms clear.
14.3 Personnel in Trough Zone
Bridge motion halts immediately on photo-eye trip. Do not reset photo-eye interlock until area is physically confirmed clear by two personnel.
If bridge is in motion at trip: motion stops and holds. Issue verbal all-clear. Confirm person is clear of trough zone. Supervisor resets DUMP-PEC-INTRUSION alarm with physical key switch.
If person entered trough: immediate medical assessment. Trough zone is APS-maintained negative pressure environment — monitor for any inhalation effects. Call emergency services.
14.4 Li-Battery or Energetic Material — Post-Ingest Detection
If energetic material is detected in trough or on conveyor after rear discharge: follow Section 11 Li-Battery Protocol. Do not continue walking floor operation if smoke or thermal event is detected. Initiate trough isolation — stop walking floor, halt downstream conveyors, notify fire services. Refer to OPS-002 Section 11.1 for full detection and quarantine sequence.
14.5 Loss of Facility Power
On power loss: all bridges hold position (fail-safe hydraulic lock — no power required to maintain position). All chocks remain engaged (fail-safe powered-to-release design). All airlock doors hold closed (spring-return fail-safe). Emergency generator starts automatically within 30 seconds — APS fans restart first, then SCADA. On power restoration, Shift Supervisor must walk all bridge and chock positions before resuming truck intake.
| Emergency | Immediate Action | SCADA Action | Escalation |
|---|---|---|---|
| Fire in Feedstock Ingest building | Activate building E-stop pull cord — all doors hold. Evacuate building immediately. Muster point per site plan. | All doors freeze in current position. APS continues. NFPA suppression activates. | Emergency services. Facility emergency coordinator. |
| Li-battery thermal event at trough | Activate nearest E-stop. Do not approach. Move to muster point. | Divert gate to QA-01. Water deluge auto-activates above 120°C. | Emergency coordinator. Fire brigade. QA-01 protocol Section 11. |
| APS pressure loss during rear discharge | Stop rear discharge — lower bridge immediately per Section 10.3. | Auto-lower command issued. Alarm logged. | APS operator. Operations supervisor. |
| Bridge stuck in raised position | Stop all rear discharge operations. Do not attempt manual lowering without LOTO. | Fault state B5. All further bridge raises locked. | Maintenance LOTO procedure. Engineering on call. |
| Person under raised bridge | Activate nearest E-stop immediately. Bridge holds in current position. | E-stop logged. All bridge motion locked. | Emergency services immediately. Do not lower bridge until personnel confirmed clear. |
15. Performance KPIs
| KPI | Target | Alarm Threshold | Measurement Basis |
|---|---|---|---|
| Truck processing rate | >30 trucks/hr per lane | <25 trucks/hr sustained | SCADA load records per shift |
| Airlock cycle time | <3 minutes per truck | >5 minutes sustained | SCADA door state timestamps |
| Payload reconciliation accuracy | ≥98% of loads within ±5% | <95% in any shift | SCADA reconciliation log per shift |
| Bridge raise/lower cycle | <60 seconds each direction | >90 seconds | SCADA bridge state timestamps |
| Feedstock Ingest negative pressure | –0.05 to –0.10 in. WC at all times | Above –0.03 in. WC for >30 sec | Continuous SCADA pressure monitoring |
| Leachate zero discharge compliance | 100% — zero discharge events | Any discharge event | Leachate tank level and pump logs |
| Li-battery quarantine response time | <60 seconds from detection to divert | >90 seconds | SCADA thermal camera alarm to divert gate confirmation |
END OF DOCUMENT — CBT-PRE-OPS-002 | Rev 1 | April 2026 | CONTROLLED — CARBOTURA INC.
Pregenesis Protocol Operations | Modules 0A / 0B / 0C | Governed by CBT-PRE-OPS-001 Master Protocol
Pregenesis Protocol Operations | Modules 0A / 0B / 0C | Governed by CBT-PRE-OPS-001 Master Protocol