FermiForward

Utilities Infrastructure Project (UIP) - Subproject 1 New Chilled Water (CHW) Plant & Central Utility Building (CUB) Upgrades

Issue for Bid (IFB) - Electrical Calculations Project No.: 3-5-206B

Issue 1 | August 27, 2026

© Keys Photography

This report takes into account the particular instructions and requirements of our client. It is not intended for and should not be relied upon by any third party and no responsibility is undertaken to any third party.

Job number 288168-03

Arup US, Inc.

35 East Wacker Drive, Suite 1800 Chicago, IL 60601

USA

arup.com

Issue 1 | August 27, 2026 | Arup US, Inc.

Contents

1. Introduction 1

2. Design Criteria 1

2.1 Codes and Standards 1

2.2 Analysis and Design Software 1

3. Calculations 1

3.1 Load Analysis 1

3.2 Preliminary Fault Current Calculation 2

3.3 Preliminary Arc Flash Analysis 2

3.4 Voltage Drop Calculation 3

Appendices

Appendix A A-1

Load Analysis A-1

A.1 Equipment Load Analysis A-2

A.2 Load Analysis by Category A-3

A.3 Existing Generator Load Calculation A-4

Appendix B B-1

Preliminary Fault Current Analysis B-1

B.1 Preliminary Fault Current Analysis B-2

Appendix C C-1

Preliminary Arc Flash Analysis C-1

C.1 Preliminary Arc Flash Analysis C-2

Appendix D D-1

Voltage Drop Calculation D-1

D.1 Voltage Drop Calculation D-2

FermiForward Utilities Infrastructure Project – Sub Project 1

New Chilled Water (CHW) Plant & Central Utility Building (CUB)

Upgrades

Issue for Bid (IFB) - Electrical Calculations Page 1

1. Introduction

This calculation package describes preliminary electrical design calculations which were used for the basis of the electrical design documents for the Fermi Utility Infrastructure Project Central Utility Building (CUB) renovation and expansion. The calculations presented herein are based on the latest design drawings and loading assumptions described within, and are subject to revision in future design phases.

2. Design Criteria

2.1 Codes and Standards

The following lists supplemental electrical codes and standards applicable to the project which are considered within this calculation package.

• 2020 NFPA 70, National Electrical Code (NEC)

• Fermilab’s ES&H Manual (FESHM), including:

− Chapter 9000 – Electrical Safety

• Fermilab FESS Design Guide, latest edition

2.2 Analysis and Design Software

The following programs were used in the analysis and preparation of this calculation package:

• ETAP 22.5.0

• Internal Design Software (ArupCompute)

• Microsoft Excel

3. Calculations

Electrical calculations presented in this report include a load analysis at the main switchgear, a generator load analysis, a preliminary fault current calculation, and a preliminary arc flash analysis. The goal of these calculations is to demonstrate appropriate configuration of the new distribution equipment planned for the CUB.

3.1 Load Analysis

The load analysis calculations represented in Appendix A are categorized by distribution element. These calculations represent major equipment loads that are expected for the facility. These calculations include overall area-based allocations for small power and lighting branch circuitry. Major mechanical equipment is represented by the actual electrical characteristics included in the basis of design mechanical selections. The load analysis in this report considers all loads documented in the design drawing package. A separate analysis of Future Scenarios was provided to FermiForward which details the ultimate expected configuration of the facility, including the introduction of heat recovery chillers.

Issue for Bid (IFB) - Electrical Calculations Page 2

Additionally, the existing generator load analysis is provided in Appendix A. The calculation is used to ensure the new 350 kW generator is sufficiently sized to support the loading condition as part of the new work. The connected load is higher than the rated capacity, but reasonable demand factors were used for the removed, retained, and new loads based on the load profiles. A load shedding scheme is included in the design to ensure that the generator will not be overloaded. Loads of lesser priorities can be shed by shunting circuit breakers so loads of the highest priority always remain active. There are various systems on the generator such as the Accelerator Division system, Booster

West, Booster East, critical pumps, critical fans, heat trace, and water treatment systems. The load shedding scheme takes away some of the operational burden of running multiple systems on the generator at the same time as a safeguard to ensure the most critical loads will stay operational.

3.2 Preliminary Fault Current Calculation

The purpose of the short circuit study is to verify whether the equipment within the electrical distribution network is sufficiently rated to withstand the anticipated maximum level of fault current which may flow within the electrical system. Insufficient fault rating may lead to equipment destruction due to thermal effects and mechanical stress. The minimum short circuit current is also considered to ensure protection devices have been suitably selected to continue to operate when minimum fault current conditions are present within the distribution system.

The results of the study are used to determine the minimum AIC ratings of equipment. This study is preliminary because it used estimated feeder lengths. A final study is to be completed by the contractor with actual feeder lengths.

3.3 Preliminary Arc Flash Analysis

Arc flash evaluations, used in conjunction with company safety policy, govern the required level of personal protective equipment (PPE) when working on energized electrical equipment.

An arc flash is a combination of light and heat produced from an electric arc supplied with sufficient electrical energy to cause substantial damage, harm, fire, or injury. When an uncontrolled arc forms at high voltages arc flashes can produce deafening noises, supersonic concussive forces, super-heated shrapnel, temperatures far greater than the Sun's surface, and intense, high-energy radiation capable of vaporizing nearby materials, thereby putting personnel at significant risk if not probably protected.

To safely work on live electrical equipment, the available incident energy must be restricted to below 40 cal/cm2 at or above this limit the equipment must never be worked on whilst live regardless of experience, training received, company policy, and PPE worn.

Arc flash calculations have been carried out in accordance with IEEE 1584 2018 and include the 2 second (120 cycles) maximum arc duration in the calculations, as the equipment is located with sufficient access space around equipment for moving away from switchgear. The calculation results show some faults not clearing that is noted with the Fault Clearing Time being 120 cycles. For these instances, the faults don’t clear because of design tradeoffs made such as properly protecting transformers from overcurrent per National Electrical Code (NEC) requirements. Arc flash incident energy remains well below 20 cal/cm2 for these cases.

The arc flash analysis presented is a preliminary and simplified study focused to evaluate the incident energy available at the primary incoming equipment to ensure that this equipment is designed to achieve 12 cal/cm2. The results of this analysis are presented in Appendix C. This analysis is based on certain assumptions:

• The selected components are modeled based on the basis of design equipment, cables, and circuit breakers presented in the design documents. This assumes the following components:

− Low voltage electrical circuit breakers, distribution equipment: Manufactured by Schneider Electric

− Transformer VFI: Manufactured by Weg

− Transformer Relay: Manufactured by SEL

Issue for Bid (IFB) - Electrical Calculations Page 3

• The Utility Fault Current contribution was modeled using existing Fermilab ETAP analysis model values for

DISTR-42. The provide ½ cycle symmetrical three phase fault current and X/R ratio was used for the existing feed from Master Substation. For Kuntz Road Substation (KRS), ETAP analysis model design values were used in conjunction with feeder length estimations from KRS to CUB. Further analysis is required when actual

KRS fault current contribution values become available.

• Simplified motor contribution was added to the main switchgear bus to represent the chiller loads on the switchgear.

• Estimated feeder lengths and circuit breaker selections. Contractor to provide exact products and lengths for the Power System Studies.

3.3.1 Preliminary Arc Flash Results

The preliminary arc flash calculations show the maximum worst case incident energy for CUB equipment of approximately 9.7 cal/cm2. This is the expected value at the line side of the incoming main circuit breaker for incoming section of “SWBD-CUB-A1” and “SWBD-CUB-D1”.

3.4 Voltage Drop Calculation

The preliminary feeder voltage drop calculation estimates the length of the conductor and utilizes the design demand load to calculate the percentage of voltage dropped across the conductor. The preliminary results show all feeders have less than a 1% voltage drop without being upsized. The lift station feeder from CUB is upsized due to voltage drop.

Issue for Bid (IFB) - Electrical Calculations Page A-1

Appendix A Load Analysis

Issue for Bid (IFB) - Electrical Calculations Page A-2

A.1 Equipment Load Analysis s Sum of Total Connected

Load [kVA] Sum of Total Demand Load

[kVA] Sum of Total Demand Load with 10% Spare [kVA]

SWBD-CUB-A1 1982.1 1940.4 2134.4

SWBD-CUB-B1 2528.1 2142.8 2357.1

SWBD-CUB-C1 1798.3 1735.4 1908.9

SWBD-CUB-D1 2319.2 2214.1 2435.5

Grand Total 8628 8033 8836

Loads by DHP

DHP-CUB-A1-1 322.2 280.5 308.6

DHP-CUB-A1-2 481.2 481.2 529.4

DHP-CUB-B1-1 245.1 205.1 225.6

DHP-CUB-B1-2 539.3 460.0 506.0

DHP-CUB-C1-1 619.7 556.8 612.4

DHP-CUB-D1-1 675.2 641.9 706.1

DHP-CUB-D1-2 465.5 393.6 432.9

S-DHP-CUB-B1-1 565.1 258.84 284.7

Issue for Bid (IFB) - Electrical Calculations Page A-3

A.2 Load Analysis by Category

Distribution Equipment Sum of Total Connected

Load [kVA] Sum of Total Demand Load

(Summer) [kVA] Sum of Total Demand Load with 10% Spare [kVA]

Cooling 4131.0 4092.3 4501.6

Heating 284.5 0.0 0.0

Lighting 29.7 29.7 32.6

Power 507.9 407.3 448.1

Pump 3653.9 3485.3 3833.8

Receptacle 20.8 18.1 19.9

Grand Total 8628 8033 8836

Issue for Bid (IFB) - Electrical Calculations Page A-4

A.3 Generator Load Calculation – Existing & New Loads

Total Removed Demand Load [kVA]

Total Retained Demand Load [kVA]

Total New Load [kVA] Generator Demand

Load [kVA] Generator Demand

Load [kW]

230.4 108.8 322.0 430.8 344.8

Issue for Bid (IFB) - Electrical Calculations Page A-5

Generator Load Shedding Sequence Steps Increasing from Lowest Priority (S5) to Highest Priority (S1) Loads

Step # Step Description

Step Demand Load (kVA)

Load Subcategory Subcategory Demand Load (kVA)

Load Comments

N/A - Loads Never

Disconnected

UPS TO CRITICAL

CONTROLS LOADS,

EMERGENCY LIFE SAFETY

INVERTER

37.6

UPS 25.6

UPS also has an external maintenance bypass with secondary feed from a non-generator source.

Life Safety Inverter 12.0

Sized to maintain code-required 90 minute runtime without utility or generator source.

N/A - Loads Never

Disconnected

CUB CRITICAL STANDBY

LOADS - PRIMARY PUMPS,

REFRIGERANT PURGE,

CRITICAL HVAC, SUMP

PUMPS, HEATING AUX.

CIRCUITS

101.2

Heating Hot Water Pumps, Heating Aux. Circuits, MWP-7 69.1

Seasonal Load: Winter Peak

Refrigerant Purge Fan 3.2 Legally Required Load - Auto Operation by ODH System

Critical HVAC - Summer: Elec Room FCUs, DX Unit, Fan-4

6.0 Seasonal Load: Summer Peak

Critical HVAC - Winter: HHWP-4,5,6 (AHU freeze protection)

1.4 Seasonal Load: Winter

Peak

LCW-P1, Sump Pumps, Lift Station 8.8 Variable Load based on ground water

Gen Aux. Power, Standby RCPT Power (Control Room, Elec Rooms, Workshop), Storm Shelter Standby Inverter

12.8

S1

CUB STANDBY LOADS -

REDUNDANT HHWP, OH

DOOR, BOOSTER PUMP,

SSF'S, TUNNEL LOADS

32.0

Redundant HHW Pump (HHWP-3) 0.0 Standby load

OH Door 0.4

Domestic Booster Pump 2.8

SSF's 15.6

Existing Tunnel Loads (Stairwell Heater, Tunnel Hoists, Tunnel Lights)

13.3 Majority of Load is

Seasonal: Winter Peak

S2

CUB STANDBY LOADS -

WATER TREATMENT

118.7

100FD: New Water Treatment (MIOX Skid) 1.4

Update 1: New Water Treatment Loads (RO Skid, CIP Skid, WT Pumps)

93.5

Existing to Remain Water Treatment (Regen System Blower, Tank #4 VFD, LCW-P2, Culligan Unit, RO Tank Pumps 1 & 2)

23.8

IFB: New RO Skid (WT-3) 80.7

S3

BACKFEED TO BOOSTER

GALLERY EAST EMERGENCY

DISTRIBUTION

31.2 Booster East Backfeed 31.2

Emergency Load - Manual Backfeed; Assuming both backfeeds are not used simultaneously.

S4

BACKFEED TO BOOSTER

GALLERY WEST

EMERGENCY DISTRIBUTION

0.0 Booster West Backfeed 0.0

Emergency Load - Manual Backfeed; Assuming both backfeeds are not used simultaneously.

S5 ACCELERATOR DIVISION

AREA PANELS

29.5 Existing to Remain Panel DHP-CU-2 29.0

Existing to Remain Panel PP-CU-4 0.5

Total Demand Load (kVA): 430.8

Total Demand Load (Amps, @ 480V nominal):

Existing Generator Standby Power Rating: 250kW/313kVA

New Standby Power Rating: 350kW/438kVA

Issue for Bid (IFB) - Electrical Calculations Page B-1

Appendix B Preliminary Fault Current Analysis

Issue for Bid (IFB) - Electrical Calculations Page B-2

B.1 Preliminary Fault Current Analysis

Equipment Name Voltage [V] Preliminary ½ Cycle 3ph

Symmetrical Fault Current [kA]

S-ATS-CUB-B1-1 480 43.63

CH-1 480 41.26

CH-2 480 40.37

CH-3 480 43.10

CH-4 480 41.47

CT-1 480 22.66

CT-2 480 23.15

CT-3 480 23.38

CT-4 480 20.97

CT-8 480 22.71

CT-9 480 23.21

CT-10 480 20.83

WT-3 480 22.34

DHP-CUB-A1-1 480 43.87

DHP-CUB-A1-2 480 43.82

DHP-CUB-B1-1 480 42.51

DHP-CUB-B1-2 480 42.47

DHP-CUB-C1-1 480 45.05

DHP-CUB-D1-1 480 42.30

DHP-CUB-D1-2 480 43.16

E-INV-CUB-B1 480 21.33

E-PHP-INV-B1-1 480 6.93

E-PP-INV-B1-1-A1 208 1.45

LP-CUB-D1-1 480 27.50

PHP-CUB-A1-1 480 17.04

PHP-CUB-B1-1 480 39.83

PHP-CUB-C1-1 480 30.96

PHP-CUB-D1-1 480 9.96

PP-CUB-A1-1-A1 208 2.48

PP-CUB-B1-1-A1 208 2.86

PP-CUB-C1-1-A1 208 2.85

PP-CUB-C1-1-A2 208 2.07

S-DHP-CUB-B1-1 480 39.31

S-MTS-CUB-B1-1 480 42.10

S-PHP-CUB-B1-1-1 480 30.56

S-PHP-CUB-B1-1-2 480 32.36

S-PHP-CUB-B1-1-3 480 28.58

S-PHP-CUB-B1-1-4 480 19.20

S-PP-CUB-B1-1-1-A1 208 1.54

S-PP-CUB-B1-1-3-A1 208 1.04

Issue for Bid (IFB) - Electrical Calculations Page B-3

Preliminary ½ Cycle 3ph

Symmetrical Fault Current [kA]

S-PP-UPS-B1-1-A1 208 1.02

S-PP-UPS-B1-1-A2 208 0.96

SWBD-CUB-A1 480 51.51

SWBD-CUB-B1 480 50.34

SWBD-CUB-C1 480 54.84

SWBD-CUB-D1 480 52.58

UPS-CUB-B1-1 480 18.36

Issue for Bid (IFB) - Electrical Calculations Page C-1

Appendix C Preliminary Arc Flash Analysis

Issue for Bid (IFB) - Electrical Calculations Page C-2

C.1 Preliminary Arc Flash Analysis

Fault Clearing Time [cycles]

Incident Energy

[cal/cm2]

Arc Flash Boundary [ft]

S-ATS-CUB-B1-1 480 3.00 3.2 2.8

DHP-CUB-A1-1 480 3.00 2.4 3.1

DHP-CUB-A1-2 480 3.00 2.4 3.1

DHP-CUB-B1-1 480 3.00 2.4 3.0

DHP-CUB-B1-2 480 3.00 2.4 3.0

DHP-CUB-C1-1 480 3.00 2.5 3.1

DHP-CUB-D1-1 480 3.00 2.3 3.0

DHP-CUB-D1-2 480 3.00 2.4 3.1

E-INV-CUB-B1 480 1.00 0.6 0.9

E-PHP-INV-B1-1 480 1.00 0.2 0.5

E-PP-INV-B1-1-A1 208 120.00 2.3 2.3

LP-CUB-D1-1 480 1.00 0.8 1.2

PHP-CUB-A1-1 480 1.20 0.6 1.0

PHP-CUB-B1-1 480 0.68 0.8 1.1

PHP-CUB-C1-1 480 1.20 1.1 1.4

PHP-CUB-D1-1 480 1.00 0.3 0.6

PP-CUB-A1-1-A1 208 111.76 3.4 2.9

PP-CUB-B1-1-A1 208 120.00 5.0 3.7

PP-CUB-C1-1-A1 208 82.03 2.9 2.6

PP-CUB-C1-1-A2 208 1.5 0.0 0.2

S-DHP-CUB-B1-1 480 3.00 3.3 2.8

S-MTS-CUB-B1-1 480 3.00 3.5 2.9

S-PHP-CUB-B1-1-1 480 3.00 2.7 2.5

S-PHP-CUB-B1-1-2 480 3.00 2.8 2.6

S-PHP-CUB-B1-1-3 480 3.00 2.5 2.4

S-PHP-CUB-B1-1-4 480 3.00 1.7 1.9

S-PP-CUB-B1-1-1-A1 208 120.00 2.5 2.4

S-PP-CUB-B1-1-3-A1 208 120.00 1.6 1.8

S-PP-UPS-B1-1-A1 208 120.00 1.6 1.8

S-PP-UPS-B1-1-A2 208 120.00 1.4 1.7

SWBD-CUB-A1 480 3.09 2.8 3.4

SWBD-CUB-A1-INCOMING 480 10.87 9.7 7.4

SWBD-CUB-B1 480 3.1 2.7 3.3

SWBD-CUB-B1-INCOMING 480 9.6 8.4 6.8

SWBD-CUB-C1 480 3.06 2.8 3.4

Issue for Bid (IFB) - Electrical Calculations Page C-3

Fault Clearing Time [cycles]

Incident Energy

[cal/cm2]

Arc Flash Boundary [ft]

SWBD-CUB-C1-INCOMING 480 9.6 8.9 7.0

SWBD-CUB-D1 480 3.07 2.8 3.4

SWBD-CUB-D1-INCOMING 480 10.79 9.7 7.4

UPS-CUB-B1-1 480 1.00 0.5 0.9

Issue for Bid (IFB) - Electrical Calculations Page D-1

Appendix D Voltage Drop Calculation

New Chilled Water (CHW) Plant & Central Utility Building (CUB) Upgrades

Issue for Bid (IFB) - Electrical Calculations Page D-2

D.1 Voltage Drop Calculation

Feeder Supply From Voltage [V] Estimated Length [ft]

Load [A] Conductor

Sets Conductor

Size Percent

Voltage Drop

DHP-CUB-A1-1 SWBD-CUB-A1 480 72.4 459 4 600 kcmil 0.14%

DHP-CUB-A1-2 SWBD-CUB-A1 480 72.0 402 4 600 kcmil 0.12%

DHP-CUB-B1-1 SWBD-CUB-B1 480 72.4 554 4 600 kcmil 0.17%

DHP-CUB-B1-2 SWBD-CUB-B1 480 72.0 871 4 600 kcmil 0.26%

DHP-CUB-C1-1 SWBD-CUB-C1 480 86.9 588 4 600 kcmil 0.21%

DHP-CUB-D1-1 SWBD-CUB-D1 480 87.4 722 4 600 kcmil 0.27%

DHP-CUB-D1-2 SWBD-CUB-D1 480 91.1 603 4 600 kcmil 0.23%

E-INV-CUB-B1 S-DHP-CUB-B1-1 480 18.5 14 1 #12 0.16%

E-PHP-INV-B1-1 E-INV-CUB-B1 480 22.9 14 1 #10 0.12%

E-PP-INV-B1-1-A1 ETR-INV-B1-1-A 208 15.8 10 1 #12 0.23%

LP-CUB-D1-1 DHP-CUB-D1-2 480 26.9 20 1 500 kcmil 0.01%

PHP-CUB-A1-1 DHP-CUB-A1-1 480 40.9 107 1 500 kcmil 0.08%

PHP-CUB-B1-1 DHP-CUB-B1-2 480 30.5 225 1 500 kcmil 0.12%

PHP-CUB-C1-1 DHP-CUB-C1-1 480 81.7 147 1 500 kcmil 0.22%

PHP-CUB-D1-1 DHP-CUB-D1-1 480 72.3 85 1 #1/0 0.29%

PP-CUB-A1-1-A1 TR-CUB-A1-1-A 208 17.2 17 1 #1 0.04%

PP-CUB-B1-1-A2 TR-CUB-B1-1-A 208 16.7 75 1 #1 0.17%

PP-CUB-C1-1-A1 TR-CUB-C1-1-A 208 16.4 87 1 #1 0.20%

PP-CUB-C1-1-A2 PP-CUB-C1-1-A1 208 43.3 25 1 #4 0.27%

S-PP-UPS-B1-1-A1 STR-UPS-B1-1 208 16.3 79 1 #1 0.18%

S-PP-UPS-B1-1-A2 STR-UPS-B1-1 208 70.7 21 1 #1 0.21%

S-ATS-CUB-B1-1 SWBD-CUB-B1 480 29.4 439 2 350 kcmil 0.14%

S-DHP-CUB-B1-1 S-ATS-CUB-B1-1 480 15.4 439 2 350 kcmil 0.07%

New Chilled Water (CHW) Plant & Central Utility Building (CUB) Upgrades

Issue for Bid (IFB) - Electrical Calculations Page D-3

Feeder Supply From Voltage [V] Estimated Length [ft]

Load [A] Conductor

Sets Conductor

Size Percent

Voltage Drop

S-PHP-CUB-B1-1-1 S-DHP-CUB-B1-1 480 36.1 184 1 #4/0 0.19%

S-PHP-CUB-B1-1-2 S-DHP-CUB-B1-1 480 30.8 134 1 #4/0 0.12%

S-PHP-CUB-B1-1-3 S-DHP-CUB-B1-1 480 167.8 73 1 #1 0.73%

S-PHP-CUB-B1-1-4 S-DHP-CUB-B1-1 480 78.5 68 1 #1 0.31%

S-PP-CUB-B1-1-1-

A1

STR-CUB-B1-1-1-

A 208 7.0 129 1 #4/0 0.06%

S-PP-CUB-B1-1-3-

A1

STR-CUB-B1-1-3-

A 208 14.4 14 1 #1 0.03%

SWBD-CUB-A1 TR-CUB-A 480 103.8 4000 11 500 kcmil 0.48%

SWBD-CUB-B1 TR-CUB-B 480 96.3 4000 11 500 kcmil 0.54%

SWBD-CUB-C1 TR-CUB-C 480 75.3 4000 11 500 kcmil 0.42%

SWBD-CUB-D1 TR-CUB-D 480 86.9 4000 11 500 kcmil 0.48%

UPS-CUB-B1 MBC S-DHP-CUB-B1-1 480 20.4 40 1 #1 0.05%