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B-40-12 Design Standard For Blast Resistant Structures
B-40-12 Design Standard For Blast Resistant Structures
Petro-Canada
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TABLE OF CONTENTS
1.0 GENERAL
1.0.1 Increasing process plant integration, reduction in manning levels and the
requirement to minimize the business loss that could result from refinery
hydrocarbon explosions has resulted in the requirement that new multi-unit control
rooms shall be built as "blast resistant" structures. (See definition of "blast resistant")
(Design Criteria Refer Paragraph 6.0).
1.0.2 Blast resistant structures are defined as buildings and other structures capable of
withstanding the effects of an external plant explosion equivalent in energy yield to 1
U.S. ton of TNT at 100 feet (30 m). This generates an over pressure of 69 KPa (10
psi) for 20 milliseconds or as an alternate where design for a vapor cloud explosion
is more applicable an overpressure of 20 KPa (2.9 psi) with duration of 100
milliseconds may be used. This is approximately equivalent to the blast effects at a
distance of 75m (250 ft) from the center of an explosion involving a "pancake" cloud
60m (200 ft) and 4m (13 ft) high containing 6% ethane. In resisting such an
explosion, moderate structural damage, without collapse, is considered acceptable.
The intent is that personnel are kept safe and facilities remain operable in such an
event (MCA 3.0).
(a) Protect the control and process computer equipment to allow safe and orderly
shutdown of the process at the time of the incident.
(b) In the case of explosion and/or fire the control room operator should be safe
enough to remain at his post and perform his duties during the emergency.
(c) To preserve plant data and records of events preceding/ during any major
incident.
(d) Operation of unaffected sections of the plant outside the explosion area.
1.2 The added cost of blast protection is considered by industry to be prudent insurance
taking into account the business risk.
1.2.1 Taking into account blast resistant design guidelines, moderate structural damage is
tolerable provided it is not detrimental to the safe operation of the building during
and subsequent to the accident. Blast resistant buildings are expected to resist a
major explosion only once in a lifetime.
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1.2.2 Preferably these buildings should be single story (to minimize the area exposed to
the blast and reduce costs for protection). Where plot limitations necessitate a two-
story building, the control room shall be located on the first floor. In the case where
laboratories are included they should be 60m (200 ft.) away from the process area.
1.2.2.2 No interconnecting doors between laboratory and other rooms, structural design
should be arranged so that a laboratory explosion does not affect other parts of the
control room.
1.2.3 The top of the concrete slab on grade is to be raised a minimum of 6 inches (150
mm) above the external grade level of the surrounding process units.
1.2.3.1 Site grading is to be so as to prevent burning hydrocarbon from flowing towards the
control building.
1.2.3.2 Earthen berms should also be considered to minimize areas exposed to a direct
blast pressures and assist in preventing hydrocarbon flow towards the building.
1.2.4 Site location should be so that control rooms are upwind of prevailing wind direction,
this also reduces the potential for H S or other hydrocarbon contamination of the
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HVAC for the control room.
1.2.5 Since windows are not installed in blast resistant buildings, provision for a video
system for flare systems monitoring shall be mandatory.
2.2.1 ASCE Manuals of Engineering Practice - No. 42, Design of Structures to Resist
Nuclear Weapon Effects.
2.3.1 SG-22 Siting and Construction of New Control Houses for Chemical Manufacturing
Plants
The definition is related to corrosion film formation on exposed copper coupon after
one-month exposure. Therefore it is prudent to design HVAC systems for the later
addition of an air scrubbing system should site conditions and air intake position
indicate (by copper coupon test) a scrubber system is required. In many cases it is
possible to obtain only general atmospheric data on a site. Tests completed before
construction provide only an indication of final conditions.
4.1.1 In arriving at a floor plan a careful review of the function and occupancy of each
room should be made.
(a) A minimum of exterior doors (blast resistant doors are extremely expensive).
(f) A convenient rack room wall bounding the exterior so that instrumentation
cables from each plant can enter the building with simplicity.
(g) A minimum of "ancillary" functions are allowed, this is considered good design
practice for blast resistant control buildings, since the cost per square foot is
relatively high.
(h) The minimum elevation of the finished concrete floor below the access floor will
be 6 inches (150 mm) above the surrounding grade to ensure that the building
does not create a low pocket where explosive vapor clouds could collect.
(i) Visitors will normally be restricted to the foyer and permits for work on the units
will be issued through the wickets into the control room.
(j) The control and rack rooms will have access floors, raised 18 inches (450 mm)
above the sub-floor, while the electrical and mechanical rooms will be at the
lower elevation. A service entrance will provide direct access to both these
rooms while a ramp up 18 inches (450 mm) will allow for the movement of
equipment to the rack and the control room.
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(k) Finishes within the building will be durable and selected for minimum
maintenance. Floors within washrooms, corridors, vestibules and the foyer will
be non-slip ceramic tiles. Walls in washrooms and vestibules will be ceramic tile
while staff areas will have a washable vinyl/wall covering.
(l) Large areas of glazing shall be incorporated between the control room and
adjacent spaces to create a visually interesting and attractive environment that
can contribute significantly to staff satisfaction.
4.2 Heating
4.2.3 No direct heating at interior rooms. Heating from the air system where required.
4.3 Ventilation
4.3.1 Washroom exhaust to exterior. (Fan timed off at loss of building pressurization).
4.3.2 Direct locker exhaust. Air re-circulated through gas vapor filters.
4.3.3 Sub-floor exhaust (to avoid surface condensation). Fan off per inert gas fire
suppression system discharge.
4.3.4 Lunchroom to have return air through gas vapor filters and direct exhaust with
domestic type hoods above the ranges. Off with loss of pressurization.
4.4.1 2 Central Air units to provide 100% standby. Sized to suit ultimate load.
4.4.2 Systems operate with adequate outside air to provide building pressurization.
Design pressure to be .10 to .15" w.g. (25 to 30 Pa)
4.4.6 Centrifugal fans with modulating inlet vane dampers to facilitate variable flow rates.
4.5.1 Ceiling air diffusers suitable for draft free air distribution and variable flow rates.
4.5.2 Variable air volume plus reheat to provide reasonably accurate room temperature
control with normal load fluctuations.
4.5.3 Reheat to be hot water for control units located within the mechanical
room (i.e. 80% ±).
4.6 Cooling
4.6.1 Where spacing is a concern, air-cooled condensing units should be roof mounted (2,
one per air unit) Carrier or equivalent. Suitable for operation at -10°C (50 °F) or
higher. Multiple stages plus hot gas by-pass. Electric unloaders.
4.6.2 Refrigerant piping, valves, filters, etc. plus connections to split direct expansion coils
(at the air units).
4.7.2 Steam and condensate and hot water piping requires standard thickness foam
glass.
4.7.3 Air conditioning supply air ductwork. Rigid board where exposed. Other to be
flexible foil faced.
4.8.1 Electronic Digital Control panel including programmer, monitor and keyboard.
4.8.2 Facility to control and monitor Air Unit functions including supply air temperature,
reset humidification, cooling stages, winter heating, and building pressurization.
4.8.3 Programming to include safety alarms and facility to shutdown the air systems.
4.8.4 Automatic timed cycling of air units to equalize operating time. Second unit should
start automatically with fan failure or manual off.
4.8.5 Gas Detector signals and alarms processed through the digital control panel(s).
4.8.6 Two panels (one master), if required to provide continuous system operation with
failure of one control unit. Inert gas fire suppression system interlock with air system
controls.
(a) Room Temperature: 22°C (72 °F) in Rack and Control Room.
(b) 28°C (83 °F) maximum in Electrical Room and Mechanical Room
4.8.9 Humidity
Primarily detection is for hydrogen sulphide at air intake and within the building.
Secondary detection is for hydrocarbon.
4.9.2 Fire Alarm system for all areas in addition to the inert gas fire suppression system in
protected rooms.
4.9.6 Inert gas fire suppression system type Fire Extinguishers in main input/output and
computer rooms.
5.1 Electrical design shall be in accordance with the following Petro-Canada standards:
6.1 Loads
Rectangular box shaped buildings shall be designed for blast pressures as follows:
(a) Each wall shall be designed for a peak reflected pressure (P ) of 30 kPa (4.4
t
psi) and a duration (t ) of 100 milliseconds.
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(b) Flat roof slabs and beams shall be designed for an incident downward
overpressure (P ) of 20 kPa (2.9 psi) and a duration (t ) of 100 milliseconds.
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(c) The main structural framing shall be designed for blast pressure on any one wall
in accordance with paragraph 1.1 above together with roof loading in
accordance with paragraph 1.2.
(d) External shear walls shall be designed for an incident blast pressure in
accordance with paragraph 1.2 together with the shear resulting from an
incident blast pressure in accordance with paragraph 1.1 and vertical load from
roof loading in accordance with paragraph 1.2.
(e) All blast-induced pressures shall be assumed to decrease linearly with time.
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6.1.2.1 Required dynamic resistance (R) in the direction of blast loads shall be calculated in
accordance with the procedure outlined in ASCE Manual 42, or an equivalent
acceptable method which takes into account dynamic response. Required dynamic
resistance may be calculated in accordance with the following general formula.
Where: R= P
√a + a γ
πγ 2δ (δ + 0.7)
m
Steel or Reinforced Girders which form a part of the main structural 1.0
Concrete frame and supports the roof
Other loads shall be in accordance with Petro-Canada Civil and Structural Design
Criteria B-41-1.
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6.1.3.1 Required dynamic resistance (R) to blast loads shall be combined with other loads
as follows:
U=D+L+R
Where,
L = Live loads, or their related internal moments and forces (MCS 3.3.3.1)
6.1.3.2 Required rebound resistance shall normally be considered in combination with dead
loads only (MCA 3.3.3.2).
6.1.3.3 Resistance to blast loads shall not be considered in combination with wind or
earthquake (MCA 3.3.3.3).
Shear (f ) = 0.60 f
dv y
Shear (f ) = 0.55 f
dv y
Direct tension (f )
dt
F = 0.622 √f' c
dt
Notes:
(2) Use of steels in this category requires authorization by the Owner's Engineer.
6.3.1 Reinforced concrete structures shall satisfy the following additional requirements:
(a) Frame and shear walls shall be designed in accordance with the NBC of
Canada, commentary J and K, and CSA CAN3-A23.3-M77, Clause 19.0 for
seismic design except as modified herein. Strict attention must be paid to
details in order to assure continuity, ductility, and resistance to loads in either
direction.
(b) Roof slabs and external walls shall be doubly reinforced. The amount of
reinforcement on each face shall be between 0.25 percent and 2 percent of the
effective cross-sectional area. Slabs and walls shall be a minimum of 125 mm
(5 inches) and 200 mm (8 inches) in thickness, respectively.
(c) Shear reinforcement, which is more necessary in blast resistant than in ordinary
construction, should be normal to the axis of the member.
(d) Double reinforced members with reinforcing adequately tied have much more
ductility than single reinforced members and accordingly offer great advantage
for blast resistant construction. In no case shall the reinforcing index "q",
exceed 0.45 in order to ensure ductile behavior. (The tension and compression
reinforcing ratios are p and p' respectively.)
q = (p-p' ) f
y
_________
1
f y
6.3.1.5 Joints are particularly important. They should be detailed and fabricated to ensure
ductile behavior of the completed element.
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6.3.2 Structures employing structural steel shapes shall satisfy the following additional
requirements.
6.3.2.1 All members shall be designed with stiffeners and bracing to prevent local or general
buckling before their full plastic capacities are developed (MCA 3.4.2.2).
6.3.2.2 Joints and connections shall be capable of developing the full capacities of the
connected members. The allowable stresses in bolts, and welds shall be as
specified in the plastic design portion of CSA S16.
7.1 Foundations shall be designed for the maximum values of the dynamic reactions
resulting from the following taken simultaneously in combination.
The maximum value of the dynamic reaction can be considered as the reaction to
the total structural resistance (U) applied as a static load. The duration and time
phase relationships shall be disregarded.
In no case shall the capacity of any foundation be less than the ultimate static
capacity of the structural element it supports.
7.2 Allowable dynamic soil bearing pressures shall be 80% of the ultimate capacity with
consideration of permissible total and differential settlements (MCA 3.5.2).
7.3 The foundation shall be designed so that the safety factor against overturning due to
the unbalanced lateral dynamic reactions is not less than 1.2 (MCA 3.5.3).
7.4 Passive resistance of the foundation, where required in addition to friction to resist
sliding, shall be at least 1.5 times the unbalanced lateral load. The unbalanced
lateral load is defined as the total horizontal dynamic reaction force less the frictional
resistance (MCA 3.5.4).
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7.5 For piled foundations the allowable vertical load under blast condition shall be 0.8
times the ultimate static capacity or 2.5 times the conventional allowable load, which
ever is less (MCA 3.5.5).
7.6 If piles are required to resist lateral movements of the structure under the blast
loading, batter piles may be used. In determining pile requirements, passive
resistance developed on the foundation walls and footing shall be taken into account
(MCA 3.5.6).
8.1 Doors
8.1.1 Doors in external blast resistance walls shall be designed dynamically within the
elastic range (δ = 1) for a blast impulse of 172 kPa (25 psi) for 20 milliseconds or
m
86 kPa (12.5 psi) static pressure unless blast wave attenuators are used.
8.1.2 Doors shall open outward and shall be supported on all edges by the doorframes.
No door shall be recessed more than one-half its width into the building (MCA 3.6.3).
8.1.3 Latch and hinge mechanisms shall be capable of withstanding the door rebound
resistance or a suction impulse on the door equal to one-fifth the blast impulse for
the door, which ever is more critical.
8.1.4 Blast resistant doors and associated hardware shall be designed and fabricated by a
vendor authorized by the Owner's Engineer.
8.2 Openings
8.2.1 Openings such as vent intakes and fume hoods shall be designed for blast effects.
Such openings shall by location, use of blast attenuators, or other means, prevent
entry of shock waves and debris into personnel and critical equipment areas (MCA
3.6.7).
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8.2.2 The total area of all openings, excluding doors, shall be limited to 0.0066 m per m
of the building volume. The total areas of openings on any one side of the building
shall not exceed one-half this limit (MCA 3.6.8).