New control switchgear for upgraded 14-generator plant, with generator paralleling switchgear behind.
New service entry / utility switchgear (l) and generator paralleling switchgear (r) during final stages of assembly. Spare breaker in background, just in case.
Service entry / utility switchgear (l) and generator paralleling switchgear (r) at the ready for commissioning.
Skid mounted generator on vibration isolators with radiator shroud at exterior exhaust plenum. Day tank connected to pit mounted supply and return fuel distribution lines. All prepped and ready for testing and commissioning.
Generators include dual starters and redundant batteries with insulation wrapped critical silencers hung from the deck above. Adjacent day tank on right.
Double loaded generator plant with radiators coupled to weatherproof exhaust plenums at the exterior of the structure.
All cabling installed and organized on ladder rack. New generators in foreground, compartmentalized control room and gear in background.
AST in concrete containment with generator plant beyond (roll-up door normally closed and secured).
Checking terminations, mimic board, and gauges.
Verifying gauge operation and re-racking a breaker.
Central Power Plant Expansion - Switchgear, Emergency Generators, and Fuel System Improvements
Client: Federal Express Corporation (FDX)
Summary: Federal Express Corporation (FDX) commissioned SIGMA7 to design and implement the upgrades and expansion of the Indianapolis National HUB Central Power Plant, a critical facility operating 24x7x365. The phased upgrade of infrastructure included switchgear replacement and expansion to of emergency generator plant, fuel storage and distribution systems. The strategic improvements required to maintain the growing needs and requirements of this always on-line operation, the second largest HUB in the FedEx logistics system.
FedEx selected SIGMA7 to modernize, expand, and enhance the emergency power generation plant at their Indianapolis National Hub (INDH), located on the east side of the Indianapolis International Airport. The project was driven by the continued growth of FedEx's logistics operations, the need for increased emergency power capacity, improved system redundancy, and upgraded long-term reliability.
As one of the most critical FedEx logistics facilities, the second largest in their network, the INDH requires continuous operation under any and all circumstances. From the outset, FedEx established clear requirements: the facility must remain fully operational throughout construction. Zero downtime or disruption to ongoing operations was permitted. SIGMA7 successfully delivered this comprehensive upgrade while maintaining 100% uptime, business reliability and continuity.
Located in Indiana's infamous "Hoosier Alley," the INDH faces frequent severe weather events. The weather includes tornadoes, high winds exceeding 70 mph, large hail, intense thunderstorms, and lightning. In this environment, reliable emergency power is not a convenience, it is an essential necessity to maintaining the logistics operations without disruption and the protection of the critical infrastructure.
SIGMA7's architectural and engineering teams redesigned the existing emergency power plant, significantly improving reliability, redundancy, and capacity with the facility live, on-line, and operational at all times. The project was executed in four (4) carefully planned strategic phases ensuring uninterrupted power service and continuous operational readiness throughout the more than year-long construction duration.
Project Highlights
- Replaced and expanded the generator switchgear, which was approaching the end of its service life, in support additional engine generators and future operational demands.
- Reconfigured the generator bus into three (3) configurable segments. This provides improved system redundancy, risk averse maintenance, and a reduction of the quantity of generators required for redundancy. The result - significant cost savings and operational benefits.
- Installed an additional redundant above-ground fuel storage tank, along with upgraded the fuel monitoring and gauging systems, doubling fuel capacity and increasing available run-time.
- Added five (5) engine generators to complement and expand the nine (9) engine generator plant.
- Two (2) of the five (5) engine generators were repurposed from the recently decommissioned FedEx Memphis Hub (MEMH) generator plant, the largest Hub in the FedEx system. (The new MEMH generator plant was also designed by SIGMA7.) The generators were relocated to Indianapolis, completely reconditioned and rebuilt. This provided substantial cost savings and a reduction in the construction schedule while supporting FedEx's sustainability objectives by diverting viable equipment from the waste stream.
- Serviced and upgraded the end-of-life generator intake and exhaust louver systems, including replacement of actuators and control components throughout the facility.
- Modernized the Building Management System (BMS), fire alarm system, and Emergency Power Off (EPO) systems.
Results
The completed project increased the plant's emergency power generation capacity from 17 MW (N+1) to 27 MW (N+1 at full capacity), a 58.8% increase in available emergency power capacity. The new switchgear and system reconfiguration facilitated the required resiliency and redundancy.
Most importantly, all work was completed with zero unplanned outages, allowing FedEx to maintain uninterrupted operations throughout the duration of the carefully phased project.
By combining strategic planning, innovative engineering, and disciplined execution, SIGMA7 delivered a resilient future-ready emergency power infrastructure solution supporting the ongoing growth and operational demands FedEx's second largest and important logistics hubs.
