Built, upgraded and commissioned without going down.

40 MW AI GPU data center with on-site generation Phase 2 in progress

40 MW IT · 40 MW on-site generation · NVIDIA GB300 and Vera Rubin · 415Y/240V distribution

A 40 MW data center in the Northeast built for NVIDIA GB300 and Vera Rubin platforms and powered by 40 MW of on-site generation. Cooling combines rack-mounted CDUs and rear-door heat exchangers on a technology cooling system loop, fed by a tempered chilled water loop and air-cooled chillers. The first 16 MW phase was completed in 2026. The 24 MW second phase is scheduled for delivery in 2027.

RoleEngineer of Record

140 kW GB300 NVL72 racks inside a live enterprise data center In design

1 MW pod · NVIDIA GB300 NVL72 at up to 140 kW per rack · row-based CDUs · live facility

A Fortune 100 retailer is adding a 1 MW AI pod to an operating enterprise data center. NVIDIA GB300 NVL72 racks are designed for up to 140 kW each, with support racks at 20 to 40 kW. FEA is designing the high-density power distribution and a technology cooling system loop serving row-based CDUs and rear-door heat exchangers, all inside a facility that stays in production.

RoleDesign Engineer and Commissioning Agent · 2026

150 kW racks in 2015: a 10 MW HPC conversion

10 MW · 150 kW per rack · custom heat exchangers · 480Y/277V to the rack

Completed in 2015 for a research client, a decade before AI made this density common. The racks held custom-built ASICs at 150 kW each, cooled through custom heat exchangers on a tempered chilled water loop and powered at 480Y/277V. FEA converted an existing facility to carry the 10 MW load by putting spare substation capacity and central utility plant chilled water to work, instead of building new infrastructure.

RoleEngineer of Record and Commissioning Agent

From 3 kW to 20 kW per rack, in place, for a global media company

1,350 kW critical IT · 3 → 12–20 kW per rack · N+N power and chiller plant · no shutdown

A client since 1995 had a 5,000 square foot data center it could not afford to lose and could not properly cool: the air conditioning could handle only half of the redundant UPS capacity, the power system had single points of failure, and equipment could not be maintained. FEA developed four options, from upgrading in place to building new, with cost, schedule and risk for each. The client chose to upgrade in place.

The old cooling system came out in three phases, a third at a time, with temporary cooling installed and commissioned before each demolition. New substations refed the existing ones so that losing either source no longer takes down all cooling. In 2025 FEA completed a high-density upgrade that delivers power and cooling for 12 to 20 kW per rack in select pods.

RolePrime professional; MEP-FP design, construction administration and commissioning

Live upgrade of a 20-year-old financial services data center

6 MW MV generator plant · new MV substation · 30 CRAH units · ~$500,000 utility incentive

Completed in 2016. The client was committed to its building and wanted another twenty years from it. FEA replaced thirty CRAH units with larger-coil units, heat exchangers and chimneyed return plenums to maximize free cooling, earning close to $500,000 in utility incentives. A new air-cooled chiller plant now backs up the water-cooled plant and carried the load at N+1 while the older plant was replaced.

Every new system was installed and fully commissioned before load transfers, and cutovers were made on de-energized circuits with no interruption to critical load.

RoleMEP-FP design; Level 1 through 5 commissioning

UPS replacement across three live data halls In progress

6 UPS systems · 12 × 800 kVA modules · temporary UPS · zero impact to critical load

A financial services client is replacing the original UPS systems in a three-hall production data center, one system at a time. Each system's load moves to a temporary UPS through the maintenance wrap-around circuit so the old modules and switchgear can be de-energized and replaced. FEA commissioned the temporary UPS and has commissioned and cut over two of the six systems so far, with no impact to critical load.

RoleCommissioning Agent

Twin 20 MW generator plants, campus refeed and 10 MW of peak shaving

2 × 20 MW 13.8 kV plants for 2N · EPA Tier 4 Final · 16 buildings on 123 acres · 10 MW peak shaving

FEA has been this campus's medium-voltage engineer of record since 1995. Over two phases, completed in 2007 and 2014, the original 10 MW plant was replaced by two 20 MW utility/generator paralleling plants, and every campus load was moved to redundant 13.8 kV circuits through a network of 68 manholes. Loads were sorted into non-critical, critical and super-critical, each with its own topology and its own load-shed and transfer sequences.

The second plant's nine 2.5 MW generators use selective catalytic reduction and diesel particulate filters to meet EPA Tier 4 Final. During an extended blackout in 2011, the first plant ran continuously for eight days without incident. In 2020 FEA added four 2.5 MW natural gas generators that run in parallel with the grid to shave peak demand.

RoleEngineer of Record and Commissioning Agent; power system studies

5 MW utility/generator plant and corporate campus refeed

13.8 kV · four utility services consolidated into one · three loop circuits by criticality

Completed in 2016. Four separate utility services were replaced with a single medium-voltage distribution system fed from new utility/generator paralleling switchgear. Critical loads have primary selection; standard loads are on open loops. Temporary services kept the campus running through each change-out.

RolePlanning, design, construction administration, commissioning and power system studies

13.8 kV generator plant for a campus data center

5 MW · 480 V plant replaced at 13.8 kV · no interruption to the data center

After a multi-year refeed that gave every campus substation redundant feeders and primary selection, FEA replaced the data center's 480 V generator plant with a 13.8 kV plant in 2015 and reworked its medium-voltage service. The work was done without interrupting data center operations, and made room for a new 2 MW double-ended substation for cooling.

RoleDesign Engineer and Commissioning Agent

Commissioning of an 8 MW modular data center

Up to 8 MW IT · 80,000 SF · designed to Uptime Institute Tier IV · LEED Gold

Completed in 2018. A new data center with a central support building and three modular wings: one for water-cooled mainframes, one for distributed computing and one for expansion. FEA commissioned the medium-voltage switchgear, substations, standby power, UPS and battery systems, chilled water and CRAH systems, fuel storage, fire protection, and a geothermal loop that provides free cooling.

RoleCommissioning Agent

Fourth data hall for a financial services two-site strategy

10,000 SF · 1 MW · Level 5 commissioning

Completed in 2019. The last shell space in an enterprise data center was built out as a fourth data hall with 1 MW of power and cooling. FEA commissioned everything from medium-voltage switchgear, generators and UPS down to branch circuits, plus EPMS, EPO, grounding, fire alarm, and the chiller plant and CRAH systems.

RoleThird-party Commissioning Agent