Blast Proof Central Command Data Center – Gulf Coast Refinery

An Exceptional Team Effort for a Unique Project

  1. Designed for Category 3 Hurricane wind speed of 130 mph (sustained winds) and Blast Design exceeds Category 5 wind speeds of 155 mph.  The bottom floor is elevated to protect from a Category 5 Storm Surge Flood.
  2. The building is in a blast zone and is designed per Baker-Strehlow-Tang Blast Pressure of 1.789 psi.
  3. Gross Area is 67,946 SF; Net Area 61,427 SF
  4. The walls facing the refinery are 12” thick concrete with 2 layers of rebar.   44,985 sf and 6,191 tons of tilt wall panels. The largest panel was 86 tons and the smallest panel was 65 tons. Average panel weighed 275 pounds per square foot.
  5. The foundation is a solid matt type with between 6 and 8 feet thick. The pour was made in one day utilizing 430 concrete trucks. Blankets and temperature sensors kept the concrete cool as it cured.
  6. 700 tons of steel, 935 tons of rebar
  7. Two 400 Ton 100% Redundant HVAC Chillers provides 72 Deg F Design Set Point for each room. (each 400 ton HVAC unit is enough to cool eighty (80) 2,500 sq ft houses.
  8. The most AC is delivered to the PCC Rack Room which receives supply air below and above floor (air delivered below floor will travel up through the cabinets, and air delivered above the floor will be from the ceiling and directed between cabinets).
  9. HVAC system will go into Shelter in Place automatically when HF, H2S or LELs are detected and can also be manually activated with a push button.
  10. A Metasys controls the HVAC system and sends warning messages long before the actual temperature changes.
  11. Ground Elevation is 10 feet, 1st floor is at 15 feet, 2nd floor is at 31 feet (Cat 3 storm 12.6 feet , Cat 4-19.5 feet, Cat 5-23.5 feet)
  12. 1st floor houses 107 production support staff.
  13. 2nd floor has the control room, Operator Simulator Training rooms, Process Control Engineer work rooms, Rack Room, Data Center and support functions such a kitchen, restrooms, lockers, conference rooms etc..
  14. 3rd floor for mechanical rooms.
  15. The building is shaped in what appears to be a curve but is actually straight wall segments. This curve design helps avoid building over the 138 KVA electrical duct bank and provides architectural interest. The panels are sized to be cast on-site and tilted into place which is safer and more cost effective than fabricating off-site. The exterior wall color is intended to match the surrounding buildings for a campus effect.
  16. Roof includes a tie-off anchor around the perimeter, roof drains so run-off does not stain the walls and a roof hatch sized for the largest piece of HVAC equipment. The roof was torch applied vs. mechanically fastened to make it the strongest roof industry can buy. The roof is the weakest link and can withstand a 4+ hurricane while rest of the building can withstand a Cat 5.
  17. Fire Protection includes a Novec gas for all control equipment, 2 hour fire rating in electrical rooms and wet pipe in the remaining areas.
  18. The Building Cost $43MM and took 16 months to construct. The CCB project is coming in under budget and on-time. Tellepsen was the General Contractor and provided a very high quality product.
  19. 138kV electrical feeds come from east and from the west for 100% redundancy with automatic transfer switches. In addition, there is at least one hour of UPS backup power. If all else fails, there are two generator hookups to the building with a gang box containing quick connects and cables for the generators.
  20. Fiber Optic cable connects the CCB in redundant, divergent paths to every unit IO room and BRM shelter in the refinery excluding Green Power and the Docks. The path was designed so no one single incident would take out both paths.
  21. Security includes badge readers and cameras.

Control Room

  1. The Control Room will currently hold 16 consoles (8 large, 8 small) and 2 spare future locations. Optimum console adjacencies were utilized to promote communication.
  2. The consoles are between 19 feet and 30 feet long with 6 foot space between consoles.
  3. The Control Room area is 9,631 square feet.
  4. An Acoustical Engineer designed the room so that normal talking at one console would not interfere with the next console operator over.  Some sound absorption features include the fur-downs, acoustical wood, sound fabric panels, angled glass, white noise, high NRC ceiling tiles and carpeting. Sound Showers direct radio and alarms directly down over the operator with almost no sound heard by the next board operator.  The board operator’s monitors are angled downward to eliminate sound travelling to the operator behind him.  The angled monitors eliminate eye and neck strain.
  5. A conference room with large glass windows overlooking the control room is provided as a “war room”. All support spaces are behind the control room.  There is at least 6 feet behind the consoles and 3 feet between them for ease of circulation.
  6. The control room is equipped with slot diffusers that distribute the air horizontally from the depressed areas in the ceiling and prevents cold air from blowing directly onto the board operator. The airflow from each type diffuser is designed to have a noise criteria less than or equal to N.C. 25 with most diffusers near N.C. 20 similar to TV studios, libraries or large churches.
  7. Locked and labeled food storage cabinets are available for each unit and each shift.
  8. A building alarm annunciator panel with horn monitors all key building functions with a gang alarm for breathing air, HVAC, Shelter in Place, Fire, Electrical, sanitary sewer trouble alarms.
  9. One hour of bottled breathing air is provided via bottled air cylinders, a medical grade delivery system and face mask at each console.


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