Natural Gas Processing

Scope of Work

• Demolition of existing natural gas storage well metering and withdrawal dehydration systems at two adjacent sites, reconfiguration of existing system at one of the sites and tie-in of all wells to new dehydration, metering and pressure regulation
• In addition to multi-discipline engineering for all disciplines, Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor document reviews

Deliverables

• Process Design Basis, PFDs and P&IDs,
• Revised Site Plan incorporating changes for storm water runoff and drainage, fencing and landscaping
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new equipment and buildings
• Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, lightning protection design, panelboard schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for demolition and installation

Projects Highlights

• Orbital adapted to client request to change dehydration technology early in the project and dehydration location mid-project due to permitting constraints with minimum impacts to overall schedule. All dehydration, metering, pressure regulation and waste stream storage and transfer was housed in a single Operations building.
• Total Installed Cost (TIC) – $10MM

345k Double Breaker Interconnect Substation

Scope of Work:

• Managed project construction through all phases of the greenfield build including civil work, below grade (ground grid, foundations, cable trench), and above grade (H-frame and steel erection, equipment setting, bus install, inside wiring, and incoming line stringing) 
• Provided safety, environmental, and quality oversight

Deliverables:

• On-site safety audits
• Daily progress reports
• Schedule tracking and input
• Requests for Information
• Non-conformance reports
• Facilitation of material deliveries/returns
• Third-party contractor coordination
• Commissioning support

Project Highlights:

• The two-year project was delivered on budget and on schedule with strong stakeholder engagement throughout its lifecycle. With no safety incidents and multiple contractors involved across major construction phases, Orbital successfully navigated complex coordination and handoff challenges by applying deep technical expertise and maintaining strict alignment with owner processes and procedures.

Federal Funded Maintenance Program Management

Scope of Work

• Lead multi-year remediation program targeting pipeline crossings, attachments, station coatings, and vehicular protection
• Developed and manage program execution for both distribution and transmission assets
• Coordinated engineering design, field documentation, and construction oversight
• Implemented phased strategy to address incomplete records, stakeholder coordination, and environmental constraints
• Updated scope to reflect evolving regulatory standards and risk assessments

Deliverables

• Engineering design packages for crossings, coatings, and protection devices
• Document control system for tracking as-builts, construction status, and compliance
• Quality assurance and quality control oversight during construction with daily/weekly field documentation
• Program tracking tools for budget, schedule, and asset-level progress
• Stakeholder communication framework to support utility, municipal, and contractor coordination
• Lessons learned and continuous improvement reports

Project Highlights

• The project successfully remediated all 23 targeted sites, and in 2024 the program expanded to include additional station coating and vehicular protection scope. The initiative supports the long-term goal of remediating over 800 assets by 2026, with an adaptable framework that accommodates evolving scope and shifting regulatory focus, providing full lifecycle support from design through construction, quality assurance, quality control, and final documentation.

Mechanical Integrity (MI) Program Audit and Development

Scope of Work:

• Performed a Mechanical Integrity (MI) audit following Department of Environmental Quality (DEQ) findings at a chemical manufacturing facility
• Conducted site walks and reviewed process documentation, including P&IDs, to identify assets requiring inclusion in an MI program
• Developed an MI asset registry, established inspection boundaries, highlighted P&IDs, and defined inspection intervals
• Built a fully compliant MI program aligned with OSHA Process Safety Management (PSM) requirements and 40 CFR 68.73
• Authored and approved extensive MI program documentation and procedures
• Developed asset-specific Inspection Test Plans (ITPs) addressing anticipated damage mechanisms and inspection requirements
• Executed baseline MI inspections using API-certified and NDT-certified inspectors
• Collected field data, photographs, inspection isometrics, and prepared detailed inspection reports
• Integrated all program documentation, inspection results, and reports into Orbital’s inspection database
• Provided ongoing MI program support, including inspections, NDT, corrosion expertise, and audit services

Deliverables:

• Mechanical Integrity audit findings and asset inventory
• MI asset registry with defined inspection boundaries and intervals
• Fully developed MI program compliant with OSHA PSM and DEQ requirements
• Over 35 approved MI program documents, including policies, procedures, checklists, and training materials
• Asset-specific Inspection Test Plans (ITPs)
• Baseline internal and external inspection reports with photographs and isometric drawings
• AutoCAD-developed inspection drawings and database-integrated records
• Ongoing inspection, NDT, and audit documentation

Project Highlights:

• Orbital developed and implemented a fully compliant Mechanical Integrity program for a chemical manufacturing facility following regulatory audit findings, providing a clear path to meeting OSHA PSM and DEQ requirements. Through a comprehensive audit and asset registry process, Orbital established a strong foundation that accounted for all applicable fixed equipment and defined clear inspection boundaries and intervals. By building the MI program from the ground up – including more than 35 tailored program documents and asset-specific Inspection Test Plans – Orbital delivered a robust, facility-specific solution aligned with regulatory standards. Baseline inspections performed by certified inspectors, combined with full database integration, positioned the client for streamlined compliance, efficient work management, and long-term program sustainability.

Orbital’s Role in Critical Structures Management Programs

Scope of Work:

• Implemented and managed plantwide Critical Structures Management Programs for multiple clients
• Performed risk ranking and structural analysis across large, complex asset inventories
• Planned and executed inspection programs based on asset criticality and risk level
• Conducted routine and advanced inspections of process vessels, exchangers, buildings, foundations, stacks, and pipe racks
• Managed inspection data, prioritization, and repair recommendations within Orbital’s database
• Developed engineered repair solutions for assets requiring non-standard or complex repairs
• Supported execution and delivery of repairs to prevent recurrence of structural issues

Deliverables:

• Risk-ranked asset inventories and inspection schedules
• Inspection reports with prioritized findings and repair recommendations
• Database-driven tracking of inspection results and mitigation actions
• Engineered repair designs and analysis for complex structural conditions
• Ongoing program management documentation and reporting

Project Highlights:

• Orbital has provided long-term Critical Structures Management Program support for one of the world’s largest refineries, overseeing inspection and risk management activities for an asset inventory exceeding 15,000 structures. By assigning risk levels to each asset and aligning inspection frequency and level accordingly, Orbital established a systematic, defensible approach to managing structural integrity at scale. Inspection findings are captured, ranked, and tracked within Orbital’s database, allowing issues to be prioritized and addressed before they escalate. When standard repair solutions are not sufficient, Orbital’s engineering team delivers customized analyses and engineered repairs, helping clients proactively manage risk, reduce repeat issues, and maintain safe, reliable plant operations.