Heavy Industrial

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.

Natural Gas Processing

Natural Gas

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

Feed Impurity Removal

Specialty Chemical

Scope of Work

• The objective of this project was to remove the oil and grease from the incoming feed flow that is utilized throughout the plant’s operations
• With these impurities being removed prior to the feed entering the Strippers, it improved the efficiency of the production at the site
• Project included installation of two oil storage tanks and six pumps with containment with all interconnecting piping, steel and supports
• A raised MCC structure on piles and a concrete pad supported transformer was added to the east of the main project area to supply power for the project and a new Delta V Cabinet with HMI was located in the new MCC building
• The existing truck parking was relocated to the northeast along with connecting existing roadways to allow for a different exit path
• New surveillance cameras were integrated with an existing camera network located at gate to the East of the proposed parking location
• Full electrical scope included adding a 13.8kV feeder, 13.8kV/480V transformer, substation building, 480V motor control center, VFD’s, UPS, panels, control stations, lighting, grounding, and associated cable tray/conduit and cables

Deliverables 

• Revised site plan
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Piping, foundation and steel drawings for supporting new tanks, pumps, MCC, transformer and piping
• Grading plans, sections and details for new roadway and parking lot
• Material requisition packages for major electrical equipment – 13.8kV switch, 13.8kV to 480V transformer, substation building, 480V MCC, UPS System
• Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, area classification drawings
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets, control narratives
• Scope of work documents for construction

Project Highlights

• Maintenance work was minimized significantly as a result of the project, decreasing downtime while increasing productivity.
• Total Installed Cost (TIC) – $120MM

Reactor Heating Process Improvement

Specialty Chemical

Scope of Work

• Orbital performed process evaluations and cost estimating for several solutions to add a new heating source to an existing reactor to allow for additional product formulation
• Following completion of FEL-2, Orbital proposed a turnkey offering for the new heat exchanger and auxiliary system upgrades to achieve the project objectives
• Orbital acted as prime for the EPC project with a mutually trusted field contractor for the client

Deliverables 

• Process Design Basis and P&IDs
• Material requisition package for the new heat exchanger
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and exchanger support structure steel drawings for supporting the new heat exchanger
• Scope of work documents for installation

Project Highlights

• Installation and commissioning were completed in 10 days due to thorough constructability planning and pre-outage construction activities.
• Total Installed Cost (TIC) – $5MM

Asset Management Program for a Steel Mill Client

Steel

Scope of Work:

• Supported a major steel client in the development and ongoing evolution of their corporate asset management program
• Provided technical assistance in creating the original corporate inspection procedure and supporting subsequent revisions
• Applied decades of hands-on inspection experience across structural and mechanical assets at domestic and international facilities
• Defined and refined inspection and reporting processes used across the client’s enterprise
• Coordinated and supported field inspection operations to align with corporate standards and safety requirements
• Integrated emerging technologies and digital tools to enhance inspection efficiency and data management

Deliverables:

• Corporate inspection procedures and revisions
• Digital inspection data outputs supporting asset tracking and long-term program management
• Standardized inspection and reporting frameworks, including:
  • Defined inspection levels
  • Standard reporting formats
  • Means and methods documents for individual assets
  • Documentation protocols
    • Boundary documents

Project Highlights:

• Orbital played a foundational role in building and evolving the client’s corporate asset management program, applying decades of inspection experience to create practical, safety-focused procedures adopted company-wide. Standardized inspection levels, reporting formats, and documentation protocols improved consistency and reliability across domestic and international operations. Through ongoing inspection programs and the integration of advanced technologies such as UAS inspections and digital data management, Orbital continues to drive continuous improvement. This long-term collaboration has helped modernize inspection practices while supporting OSHA/ANSI compliance and the client’s reliability-centered maintenance objectives.

OH-Crane, Crane Runway and Building Inspection

Steel

Scope of Work:

• Performed a comprehensive technical inspection of an industrial building, crane runway system, and overhead bridge crane at a major manufacturing facility
• Verified structural integrity of building framing and crane runway support systems
• Assessed condition and alignment of crane rails, runway beams, and associated structural components
• Conducted a full OSHA/ASME-compliant overhead crane inspection during a single coordinated site mobilization
• Deployed a multidisciplinary team of structural inspectors, scanning technicians, and certified overhead crane specialists
• Utilized aerial lifts, top-side runway access, and Elios 3 caged drone technology for difficult-to-access areas
• Performed alignment verification using Total Station surveying methods
• Applied visual, hands-on, and targeted non-destructive testing (NDT) techniques
• Executed mechanical, structural, electrical, and functional testing of overhead crane components
• Provided real-time notification of critical or out-of-service safety findings

Deliverables:

• Structural inspection findings for building framing and crane runway systems
• OSHA/ASME-compliant overhead crane inspection report
• Runway alignment measurements, including elevation, sweep, span, and cross-levelness data
• Severity-ranked deficiency listings with tagged photographs and measurement documentation
• Conceptual repair sketches for identified structural and runway deficiencies
• Preventive maintenance, repair, and long-term monitoring recommendations
• Integrated inspection report capturing all findings from a single mobilization

Project Highlights:

• Orbital delivered a fully integrated, multi-discipline inspection of an industrial building, crane runway, and overhead crane system in a single site mobilization, minimizing operational disruption and eliminating the need for multiple specialty contractors. By combining structural inspection, advanced scanning, precision alignment verification, and OSHA/ASME-compliant crane evaluation, Orbital provided a complete system-level assessment of both structural and mechanical performance. The inspection identified runway alignment deviations, localized structural corrosion, and typical crane component wear, allowing Orbital’s engineering team to develop prioritized repair recommendations and conceptual solutions. This project highlights Orbital’s ability to deliver efficient, technically rigorous inspection programs that support safe, reliable crane operations in complex industrial environments.

Bridge Inspection and Turnkey Repairs

Power Generation

Scope of Work:

• Performed a comprehensive inspection of a ~1,000-foot suspension bridge spanning a major waterway
• Utilized ground-based, elevated walkway, and rope-access techniques to evaluate hard-to-reach areas
• Benchmarked findings against prior inspection reports to identify changes and new deficiencies
• Classified deficiencies by priority level to guide repair urgency and scope
• Performed engineering analysis and developed Standard Repair Procedures (SRPs) for identified deficiencies
• Coordinated access constraints, including railroad scheduling, live powerline limitations, and follow-up inspections
• Executed turnkey repair construction for the north half of the bridge, including demolition and repairs
• Provided construction coordination, safety planning, and on-site quality oversight

Deliverables:

• Phased inspection reports as segments of the bridge were completed
• A repair prioritization ranking assigned to each finding
• Standard Repair Procedures (SRPs) and engineering repair IFC drawings for Priority 1 deficiencies
• Construction coordination and quality assurance documentation
• Final inspection report and repair verification records

Project Highlights:

• Orbital delivered a comprehensive inspection and turnkey repair program for a 1,000-foot suspension bridge, combining rope-access inspection, structural engineering, and construction oversight to address complex access and safety challenges. The inspection identified 43 deficiencies, including multiple Priority 1 conditions such as widespread cracked welds, severe section loss in a primary truss chord, and extensive concrete spalling with exposed reinforcement. Orbital executed phased reporting to support timely decision-making and completed full demolition and repairs on the north half of the bridge. When lead-containing coatings were discovered mid-demolition, Orbital paused work, coordinated with regulatory agencies, and implemented a revised, compliant construction plan – allowing repairs to resume and conclude efficiently while maintaining safety, regulatory compliance, and structural integrity.

API 653 Tank Inspection and Floor Replacement

Specialty Chemical

Scope of Work:

• Performed an out-of-service API 653 tank inspection, including a Magnetic Flux Leakage (MFL) floor scan
• Evaluated tank floor condition and investigated MFL indications using ultrasonic thickness testing (UTT)
• Documented and marked areas approaching T-minimum for repair
• Developed API 653–compliant engineering designs for complete tank floor replacement
• Designed modifications to accommodate relocation of multiple tank shell nozzles
• Defined non-destructive examination (NDE) requirements associated with repairs
• Provided on-site quality assurance and quality control oversight throughout all phases of construction and repair
• Verified completion and documentation of all corrective actions
• Prepared and issued final inspection documentation confirming fitness for service

Deliverables:

• API 653 out-of-service inspection report
• MFL floor scan results and UTT verification data
• Detailed API 653–compliant repair drawings for full floor replacement
• NDE procedures and inspection requirements
• Quality assurance and quality control oversight documentation and repair verification records
• Final inspection report confirming safe, compliant return to service

Project Highlights:

• Orbital executed a comprehensive API 653 inspection and major repair program for a 99,500-gallon storage tank, identifying floor corrosion risks through advanced MFL scanning and targeted ultrasonic testing. Early detection of low-thickness areas approaching T-minimum allowed Orbital to design proactive repairs before loss of containment could occur. The project required complete tank floor replacement and the relocation of multiple shell nozzles – complex modifications successfully delivered through Orbital’s integrated inspection, engineering, and quality assurance and quality control oversight. The repairs restored the tank to a safe, compliant operating condition, extended its remaining service life, and reduced the client’s risk of unplanned outages and future repair costs.

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.

Coal Delivery System Modification

Power Generation

Scope of Work

• Coal fired power generation facility client faced a dilemma with their existing barge unloader only capable of unloading barges up to a specific width, limiting the type of barge that can be used in delivery
• Further complicating the delivery, the barges that fit within the constraints of the unloader are becoming less available due to age
• Orbital developed conceptual solution for a new barge unloading system that allowed for unloading jumbo barges to the existing surge bin via deck mounted Sennebogen cranes, hoppers and conveyors on a new deck barges and incline conveyors to the existing surge bin
• Once approved, Orbital executed detailed design including procurement support in equipment specification and selection, owner’s engineering and construction support

Deliverables

• General arrangement drawings and total installed cost estimates for various solutions
• Material requisition packages for conveyors and hoppers
• Conveyor support steel drawings and foundations
• Single line diagrams, power plans, lighting plans, grounding plans, cable & conduit schedules
• Scope of work documents for construction

Project Highlights

• Project was originally deemed an “unsolvable problem” due to complexities in the design interfaces, contractual interfaces between delivery and client and limited remaining operating window for the facility. Orbital’s efficient solution allowed for the project to be authorized, and the facility is currently conducting coal unloading operations via the new unloading system. The facility operating permit has been extended since project completion making the solution benefits realized well into the future.
• Total Installed Cost (TIC) – $4MM

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.

ISBL Process Unit and Tank Farm

Petrochemical

Scope of Work

• Project included facility expansions of tank farm, truck loading, pipe rack, two transformers, service lines and cable tray
• The tank farm scope included pedestals for field-fabricated tanks, shop-built tanks, containment walls and pump gallery
• 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 storage tanks and transformers
• Revised site plan
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new tanks, piping and cable tray
• Single line diagrams, power plans, cable tray plans, lighting plans, grounding plans, cable & conduit schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets for OSBL scope
• Scope of work documents for construction

Project Highlights

• Orbital interfaced with the client and third-party technology provider to coordinate the process, mechanical and piping design of the ISBL process unit.
• Total Installed Cost (TIC) – $52MM

Tank Farm Expansion

Petrochemical

SCOPE OF WORK

• Developed FEL-2 engineering and +/- 30% estimate for 30 new tanks and tank farm infrastructure
• Interfaced with tank vendor for required design modifications for EPA compliance
• Developed scopes of work and quantities for all disciplines and total installed cost estimate in Aspen Capital Cost Estimator

PROJECT HIGHLIGHTS

• Total installed cost estimate of $80MM
• Client awarded FEL-3 engineering as sole source and majority of detailed design to Orbital after successful FEL-2 execution.

Glass Lined Reactor Additions

Specialty Chemical

Scope of Work

• The project modified an existing unit to accommodate the addition of three new glass lined reactors, numerous acid and caustic tanks
• A new bulk material handling and storage building was added along with a Redler material handling system to move the cohesive solids to the reactors
• Truck unloading for acid and caustic were installed and two new 750 HP boilers, water well and cooling tower were also added
• Approximately 4000 linear feet of product lines were run from the site to tie in at the adjacent plant
• 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 glass lined reactors, tanks, material handling systems, boilers and cooling tower
• Revised site plan
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new equipment and building
• Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, panelboard schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for construction

Project Highlights

• Entire project from award to completion was executed to a very aggressive schedule of 13 months.
• Total Installed Cost (TIC) – $15.8MM