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Central Power Plant - Utility Substation, Emergency Generators, UPS Systems, and Redundant Service Distribition

Client: Federal Express Corporation (FDX)

Summary: Federal Express Corporation (FDX) commissioned SIGMA7 to develop and design their new upgraded Central Power Plant in support of the growing needs of the Memphis Super HUB facility. The new infrastructure includes a utility substation and switch yard, redundant service distribution, and emergency generator back-up to maintain 24/7/365 operations at the busiest airport overnight in the world.

The FedEx World Super HUB located in Memphis, TN, stands as a colossal sorting and distribution facility within the global FedEx shipping system. Often dubbed “the busiest airport overnight in-the-world,” this hub handles an astounding 2.5 million packages in a single 24-hour period. As packages traverse from shipper to recipient, many pass through this bustling facility.

The existing power grid, based upon historical data and ongoing performance, is not able to provide consistent reliable electrical service to support and satisfy ongoing operations and increasing needs of the FedEx HUB Campus operation. FedEx cannot afford to compromise the integrity, criticality and time sensitive nature of their operation and business model.

To address this concern, FedEx turned to SIGMA7 for assistance.

SIGMA7’s reviewed and evaluated the existing infrastructure and scrutinized the proposed masterplan for the $2 billion expansion of the HUB and related facilities at the airport. Following SIGMA7’s architectural and engineering review and analysis of the current and future planned growth in addition to the expansion initiatives, it was clear that the original design concept required updating to meet the growing needs of the operation. Simply replacing the existing generator building with an updated facility would not be sufficient. The power needs and electrical capacity requirements were far greater than originally planned.

The FedEx team agreed with SIGMA7’s findings. It was determined that a structure double the size with twice the infrastructure capacity would be initially required. Further, the updated design was to incorporate provisions to double the capacity of the initial build-out to accommodate the long-term projected needs of the facility.

The focus of the infrastructure facility was re-aligned based upon the updated findings and moved onto the review of the public utility infrastructure. Given the ongoing history and concerns for the grid, it was also agreed that the construction of a new utility substation would not only beneficial for the ongoing reliability and performance of the facility, but essential for ensuring reliable power supply to the FedEx Super HUB.

The project’s updated goals and objectives were clear: Plan a new Central Power Plant to anchor the Super HUB’s operations. This would include resolving the ongoing utility power issues, proactively addressing the projected increase in operational capacity, and ensuring that the electrical infrastructure could provide for organic growth as well as the projected long-term needs anticipated to accommodate the up and coming $2 billion HUB expansion project.

The project team commenced work on the design of the new substation and their collaboration with the public utility on the underground power distribution that would serve the central power plant and the circuits required to support other critical facility operations within the FedEx HUB Campus.

Select features of the new central power plant, substation and the underground power distribution system include:

Central Power Plant Structure

• Structure steel frame with insulated precast concrete shell and reinforced concrete roof deck
• A hardened facility engineered to withstand natural disasters. It is earthquake, hurricane, and tornado resistant
• The design is LEED compliant and certified

Central Power Plant Infrastructure

• Plant design based upon 12MW modular system
• Each system consists of four (4) - 3MW generators
• A 12MW ‘catcher’ system module is provided for increased reliability
• Design provides for concurrent maintainability to accommodate service or equipment outage of a generator or an entire system
• Initial capacity of the central power plant is 48 MW of Emergency (Generator) Power.
• Ultimate capacity of 96 MW
• Plug-and-play rotary UPS backup provisions included in infrastructure design

Substation and Switch Yard Design

• The team collaborated with the public utility on the robust Substation and Switch Yard
• The substation’s capacity is 100 MW at 161 kV

Transmission Lines

• Designed and coordinated 2.5 miles of 161 kV utility transmission lines with the utility company and half-mile redundant underground utility distribution system connecting the Central Power Plant to the Substation Switch-yard
• Coordinated installation and approvals with multiple utilities and suppliers including the airport jet fuel pipeline

The development and design of the new central power plant, substation, and utility service distribution represent a significant advancement toward enhancing the reliability and robustness of the power grid serving the FedEx Super HUB at their Memphis Airport Campus. With a focus on redundancy, concurrent maintainability, and well-structured distribution, this upgraded infrastructure aims to ensure the supply of uninterrupted and stable power for the critical operations of the HUB.

The recent celebration of the Building's Topping-off was celebrated in January 2024, marking a significant milestone in the construction process. Work continues, with the facility is anticipated to be fully operational by the second quarter of 2025. The FedEx World HUB will soon benefit from a more resilient and dependable power system, supporting its vital role in global logistics and package delivery.

This page will be updated as construction progresses. 

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