See How We Deliver
From design through delivery, engineering the systems that support heavy industries and utilities since 1969.
Heavy Industrial
ISBL Process Unit and Tank Farm
Petrochemical
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
Asset Management
API 653 Tank Inspection and Floor Replacement
Specialty Chemical
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.
Heavy Industrial
Water Intake Modification
Steel
Water Intake Modification
Steel
Scope of Work
- Evaluate options for compliance with the EPA Clean Water Act section 316(b) for intake structures
- Upon option selection, executed engineering services for integrating the new solution into the existing 100-year-old pump house
- Orbital performed detailed engineering required to support construction of the new intake technology modifications and supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review
- Orbital provided construction management onsite through the demolition and installation activities as well as provided review of contractor field submittals for shop steel detailing and concrete
Deliverables
- Material requisition packages for all equipment and bid packages for all contractors
- P6 schedule development for entire project through commissioning
- Site plan including underground piping and excavation
- Equipment mounting installation details
- Navisworks model, general arrangement drawings, piping plans, sections & elevations
- Foundation and steel drawings for supporting the new intake system, piping and electrical infrastructure
- Single line diagrams, power plans, MCC drawings, lighting plans, grounding plans, cable & conduit schedules, conduit routing plans, panelboard schedules
- Instrument datasheets, I/O list, instrument index, control system narrative, control system architecture drawing, wiring drawings
- Scope of work documents for demolition and construction
Project Highlights
- In review of regulations, Orbital proposed solution to establish compliance by lowering velocity rather than installing fish return which saved client approximately $13MM over originally conceived client options.
- Total Installed Cost (TIC) – $20MM
Heavy Industrial
Coal Delivery System Modification
Power Generation
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
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
Asset Management Program for a Steel Mill Client
Steel
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.
Featured
Federal Funded Maintenance Program Management
Natural Gas
Federal Funded Maintenance Program Management
Natural Gas
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.
Heavy Industrial
Hot Oil Heater Replacement
Specialty Chemical
Hot Oil Heater Replacement
Specialty Chemical
Scope of Work
- Executed FEL-3 engineering and detailed design for a hot oil heater replacement
- Project aimed to reduce fuel consumption by replacing an oversized hot oil-fired heater with a smaller, more efficient unit
- The replacement unit would still burn natural gas and fuel oil with incremental reductions in greenhouse gas emissions
- During the FEL stages, an alternate ethanol fired hot oil heater was investigated with the facility using spent ethanol as the primary fuel for the burner instead of natural gas and fuel oil
- Orbital performed conceptual design for integrating both options complete with total installed cost estimate for each option. Owner decided to proceed with the ethanol fired heater option
- Orbital supported construction activities through bid walks with each field contractor, responding to inquiries during bid clarifications, evaluating bids and providing recommendation on contractor for award
- Orbital performed construction management during key construction activities
Deliverables
- Process design basis and P&IDs
- Material requisition packages for hot oil heater and ancillary equipment (pumps, tanks, filters)
- Navisworks model, 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
- Scope of work documents for construction
Project Highlights
- The ethanol fired option, while more expensive, allowed the facility to reduce their greenhouse emissions by 50% making significant impact on their sustainability goals.
- Total Installed Cost (TIC) – $4MM
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
