Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
Heavy Industrial
Chemical Plant
Specialty Chemical
Chemical Plant
Specialty Chemical
Scope of Work
- Project included the installation of two new reactors into an existing enclosed facility
- Laser scanning was conducted to collect field data for the 10-level existing facility
- One new reactor was tied into the existing DCS system with the other reactor expected to be tied in at a later date
Deliverables
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Steel drawings for supporting the new reactors, piping and conduit
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Laser scan data supported constructability reviews and definition of demolition needed to lower the 2 new reactors through the roof and down to level 3.
- Total Installed Cost (TIC) – $3.2MM
Heavy Industrial
Gum Treatment Project
Specialty Chemical
Gum Treatment Project
Specialty Chemical
Scope of Work
- This project included the installation of a new 40 ft tall retention tanks, 4 plate and frame exchangers, 25 ft tall feed tanks and centrifuge within multi-level process structure, cooling tower, inline mechanical shear mixer, clean-in-place (CIP) system (pump, tank, and controls), air purge system, multiple pumps (centrifugal and PD), and piping
- Orbital developed the FEED package and executed detailed design and construction management for the project
Deliverables
- Process design basis, PFDs and P&IDs
- Material requisition packages for all process equipment
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting new equipment, piping and cable tray
- Single line diagrams, power plans, cable tray plans, lighting plans, grounding plans, cable and conduit schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Spooling and prefabricated steel allowed above grade construction to be completed during a fast-track turnaround of 14 days.
- Total Installed Cost (TIC) – $6MM
Heavy Industrial
Truck Scale Addition
Petrochemical
Truck Scale Addition
Petrochemical
Scope of Work
- The primary goal of this project was to install a new truck scale and automation to improve operating costs reducing filling times and operator interfaces and provide an opportunity to load a separate product
- Orbital performed detailed engineering required to support construction of the new scale and automated system, procurement activities for securing components needed for the project, and field construction management activities
Deliverables
- Revised P&IDs and general arrangements
- Structural pipe supports drawings, access platform and hose manifold supports
- Scale pit design and drainage drawings, sidewalk and paving modification drawings
- Schematic wiring diagrams, and cable and conduit schedules
- Scope of work documents for construction
Project Highlights
- Project significantly reduced operator exposure and human factors through successful process automation.
- Total Installed Cost (TIC) – $8 MM
Featured
138kv System Reliability Project
Oil and Gas
138kv System Reliability Project
Oil and Gas
Scope of Work
- Option evaluation to improve reliability of the existing 138 kV ring buses as recent incidents disrupted operations at the facility
- Objective of the first phase of the project was to select a viable solution to increase reliability to prevent similar disruptions in the future
Deliverables
- Reliability risk identification report with conceptual solutions
- For each proposed option:
- One-line diagrams
- General arrangement drawings
- Total installed cost estimates
Project Highlights
- Project was jointly executed between Orbital’s Utility and Heavy Industrial division to interface with Utility and client for one team execution in review of client risk areas and proposal of design modifications. Capabilities on both sides of the Utility connection allowed for single firm consultation reducing client need to contract to and facilitate information exchange between multiple firms.
Heavy Industrial
Fuel Certainty
Power Generation
Fuel Certainty
Power Generation
Scope of Work
- A severe weather event (hurricane) led to local utility assessing plant readiness to operate continuously in the event of interruption due to primary fuel curtailment
- The project goal was to improve the reliability and capacity of plant secondary fuel operations.
- At two separate dual fuel facilities, Orbital:
- Evaluated current capabilities and limitations
- Performed investigations to reduce unknowns and minimize risks
- Identified and evaluated various options to increase capabilities
- Developed cost estimate to assist in option evaluation and project funding request
- Participated in option selection and finalization of detailed project scope
- Performed detailed design for implementing the selection options at one of the facilities
Deliverables
- Process evaluation report, equipment list and material requisition packages for equipment
- General arrangement drawings, piping plans and isometrics
- Foundation plans and structural steel drawings
- Single line diagrams, power plans, lighting plans, grounding plans, cable & conduit schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Total installed cost estimates at each FEL stage to support client stakeholder gate reviews
- Scope of work documents for construction
Project Highlights
- Facilities have since experienced more severe weather events without impacting generation capabilities.
- Total Installed Cost (TIC) – $10MM
Heavy Industrial
Wastewater Treatment
Petrochemical
Wastewater Treatment
Petrochemical
Scope of Work
- Executed detailed design for a licensed technology provider integrating their wastewater treatment package into an existing client facility
- Orbital acted as engineer of record for the design required for the field construction packages
Deliverables
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting new equipment and pipe racks
- Single line diagrams, power plans, cable tray plans, lighting plans, grounding plans, cable & conduit schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Orbital successfully interfaced with three local installation contractors for civil, mechanical, and E&I respectively, to support the licensed technology provider in delivering a successful turnkey offering to the client.
- Total Installed Cost (TIC) – $17MM
Asset Management
Emergency Response Support – Critical Failure
Steel
Emergency Response Support – Critical Failure
Steel
Scope of Work:
- Responded to an emergency inspection request following a critical failure at the Pipe Bridge end panel connection
- Performed on-site damage assessment after debris accumulation led to moisture intrusion, deterioration, and structural failure
- Deployed an emergency response team to collect field data and evaluate the condition of the truss system
- Analyzed structural distress across the Pipe Bridge, including overstressed members and failed connections
- Designed temporary shoring and permanent repair solutions
- Provided construction-phase engineering support through restoration and return to service
Deliverables:
- Emergency inspection and condition assessment findings
- Structural calculations evaluating end reactions and overstressed members
- Temporary field support and shoring designs
- Detailed repair packages for permanent restoration
- Construction support and oversight documentation
Project Highlights:
- Orbital’s rapid emergency response following a critical Pipe Bridge failure minimized risk and accelerated recovery for a facility experiencing prolonged operational disruption. The team assessed extensive structural distress within a 384-foot truss system, identifying hundreds of overstressed members and extreme end reactions approaching one million pounds. By quickly designing temporary support systems and permanent repairs, Orbital restored structural integrity and returned the Pipe Bridge to service. The successful execution of complex field repairs, including extensive welding and construction oversight, demonstrated Orbital’s ability to manage high-risk structural failures under demanding conditions.
Featured
Blast Furnace Gas Main Replacement
Steel
Blast Furnace Gas Main Replacement
Steel
Scope of Work
- Design blast furnace gas main replacement
- Supported project from early stages of existing facility documentation research, infrastructure inspection and utility investigation through flow modeling, detailed design and construction management
- Led shutdown planning following review of existing isolation (valves, blinds) and design incorporation of new isolation where required
Deliverables
- Flow model for confirmation of gas main sizing
- Goggle valve replacement packages including design drawings, sections, details and scope of work
- Inspection reports, standard repair details and engineering repair and replacement drawings, where required
Project Highlights
- Project showcased the uniqueness of Orbital with full-service asset integrity investigation and engineering solutions from one firm.
- Total Installed Cost (TIC) – $25MM
Asset Management
Mechanical Integrity (MI) Program Audit and Development
Specialty Chemical
Mechanical Integrity (MI) Program Audit and Development
Specialty Chemical
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.
