Heavy Industrial

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.

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.

Crude Storage Tank

Oil and Gas

Scope of Work

• Execution of FEL-2, FEL-3 and detailed design.  Total installed cost estimates and project schedules supported Owner gate approvals at each stage
• Project added 325,000 BBL tank, pumps, heaters, mixers, firewater/foam system, MOV’s, VFD’s and High Mast Lighting
• Orbital executed multi-discipline engineering for all disciplines

Deliverables

• Process design basis, PFDs and P&IDs
• Material requisition packages for tanks, pumps and other equipment
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new tanks, pumps, piping and electrical infrastructure
• Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable and conduit schedules, panelboard schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for construction

Project Highlights

• Pipeline pumps, connections and controls were made to tie this scope into a tank farms 35 miles away.
• Total Installed Cost (TIC) – $25MM

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

Substation Relocation

Specialty Chemical

Scope of Work

• Existing client 34.5kV main substation was approaching the end of its useful life
• Orbital performed electrical and structural engineering to relocate the substation out of a central process area to eliminate overhead high voltage cable in the congested space
• Orbital subcontracted geotechnical and architectural services with trusted partners for a comprehensive offering

Deliverables

• SKM Model
• Revised site plan
• Single line diagrams, substation layouts, cable tray and conduit routing plans
• Foundation drawings, support details and cable tray bridge drawings
• Scope of work documents for construction

Project Highlights

• Project required interfacing with the utility to review impacts to the existing 34.5kV pole-mounted metering equipment and their upstream overhead distribution system. Orbital performed calculation comparison between the existing and new equipment to determine what incentives applied to the project for the client to pursue. Orbital led constructability planning sessions with client, Orbital and contractor to efficiently sequence the demolition and installation scopes.
• Total Installed Cost (TIC) – $10MM

Asset Management Program for Power Generation Client

Power Generation

Scope of Work:

• Reviewed and developed corporate inspection procedures and standards for a Power Generation client
• Collaborated with client stakeholders to align documentation with industry standards and practical, field-validated inspection methodologies
• Established inspection criteria for plant structures
• Developed and introduced a new “Ready-to-Fall” risk assessment methodology to evaluate potential structural and attachment failures
• Supported post-acquisition integration by creating a phased implementation plan for newly acquired facilities to align with the corporate inspection program

Deliverables:

• Updated corporate inspection procedures and standards documentation
• “Ready-to-Fall” risk assessment framework, including:
  • Visual condition rating criteria
  • Risk scoring based on likelihood and severity
  • Mitigation timelines to guide maintenance actions
• Phased implementation plan to support onboarding of newly acquired facilities into the corporate inspection program

Project Highlights:

• Orbital strengthened the client’s structural integrity program by pairing field-validated inspection procedures with a quantitative, risk-based methodology for managing degradation and fall hazards. The introduction of the “Ready-to-Fall” assessment model provided clear, defensible prioritization for stabilization, barricading, and repair actions across the client’s fleet. These improvements led to a measurable reduction in safety incidents related to structural failures and improved regulatory compliance across all facilities. Orbital’s approach elevated inspection practices from reactive evaluations to a proactive, data-driven strategy supporting safer, more reliable plant operations.

Black Liquor Storage Tank

Specialty Chemical

Scope of Work

• Project included facility addition of a field fabricated tank, pumps, rake and new MCC building
• Orbital executed detailed design and supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting

Deliverables

• Material requisition packages for tank, pump and new MCC building housing new electrical equipment
• 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 and conduit schedules
• Scope of work documents for construction

Project Highlights

• Alternate foundation design proposed in the early FEL stages of the project resulted in savings of over $500,000 to the client.
• Total Installed Cost (TIC) – $12MM

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.

Orbital’s Role in Critical Structures Management Programs

Oil and Gas

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.