Projects

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

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.

N2 Feed Gas Compressor Replacement

Oil and Gas

Scope of Work

• Replaced existing feed gas compressor with a new compressor in same location
• Scope included process, piping, structural, electrical and instrumentation design activities
• Design considered pipe spooling to the maximum extent and shutdown planning for MCC modifications
• Orbital led constructability reviews to identify lifting locations and equipment staging areas for the quick turnaround window

Deliverables

• Revised P&IDs and general arrangements
• Piping plans, sections & elevations, isometrics
• Structural pipe supports drawings, compressor skid anchorage and grouting details
• Single line diagrams, cable & conduit schedules and grounding plan
• Schematic wiring diagrams, instrument list and instrument installation details
• Scope of work documents for construction

Project Highlights

• Successfully completed compressor replacement with minimal downtime. The existing compressor was demolished, and new compressor was installed and commissioned in same location in just 4 days.
• Total Installed Cost (TIC) – $2MM

Management Programs

Construction Management

Roles and Responsibilities

• Enforce stop work authority
• Hold construction crews accountable for compliance with owner safety processes
• Oversee execution of daily job safety briefings
• Ensure adherence to all site-specific safety and environmental plans
• Investigate and report on incidents
• Ensure required permits are maintained
• Support pre-construction planning, review drawings and bill of materials to avoid delays
• Oversee schedule performance and contribute to the development of schedule recovery plans
• Monitor construction quality by verifying compliance with drawings and specifications and preparing non-conformance reports
• Facilitate the request for information process
• Coordinate material and equipment deliveries
• Manage material inventory
• Support subcontractor assignments
• Maintain organized project records such as redlines, photos, and equipment data for final turnover at project closeout

Program Highlights

• Orbital supports investor-owned utilities throughout the country with dedicated teams of construction managers and quality management professionals. With nearly 100 boots-on-the-ground resources, Orbital’s construction management teams play a critical role in the safe and successful execution of more than $750MM in construction work annually. Through robust onboarding and continuous education programs, Orbital’s teams have the capability to support a variety of projects including new build substations, substation equipment upgrades, new build overhead transmission and distribution lines, grid modernization, underground cable replacement, overhead and underground fiber builds, and communications structure erection.

138kV Substation Expansion

Substation Engineering

Scope of Work:

• Completed design to interconnect new 25MW battery & 100MW solar facility to existing substation
• Expanded existing 138kV ring bus and add one new 138kV breaker position
• Required temporary configuration of existing 138kV line to facilitate construction
• Engineered two new monopoles and one H-frame to reconnect transmission line to expanded station
• New control building with new fiber connection to support protection and controls, and telecommunications

Deliverables:

• Detail design and construction package
  • Drawings – demolition, protection and control, physical, civil, transmission line with load trees
  • Studies – ground grid, foundations, substation structures, transmission line structures
  • Review vendor drawings for equipment, engineered structures, and calculations
• Construction support
• Incorporate as-built drawings post-construction

Project Highlights:

• Orbital Engineering navigated precise construction sequencing including temporary configurations to enable site build out while limiting downtime. Design included the relocation of existing transmission line to successfully expand the substation for the new solar and battery facility interconnection.

345k Double Breaker Interconnect Substation

Construction Management

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.

Inlet/Outlet Valve Evaluation

Natural Gas

Scope of Work

• Performed GIS and records-based analysis of 1,617 gas regulating stations
• Evaluated compliance with inlet/outlet critical valve design standards
• Validated valve data from GIS and Maximo using spatial analysis and attribution logic
• Assigned station risk ratings based on valve presence, type, and quantity
• Developed formal reclassification, design, and investigation workflows for 1,100+ non-compliant stations
• Recommended future valve placement or conversion to critical designation using industry standards

Deliverables

• Executive summary and class 5 capital planning estimate
• G.A.C.-coded dataset with risk priority assignments 
• Planning template outlining time estimates by station priority level
• Engineering design trigger list for non-compliant or undocumented stations
• Reclassification workflow diagram and phase 3 execution guidance
• GIS shapefiles for pipelines, stations, valves, and analysis overlays
• Maximo/GIS data cleanup recommendations and asset tracking integration

Project Highlights

• The team analyzed 1,617 stations across the service territory, finding that approximately 32% were compliant, 44% required formal design, and 24% were convertible through reclassification. They introduced a desktop validation and G.A.C. priority framework to streamline program actions, supported program execution with valve planning templates and phase 3 task sequencing, and applied the client’s gas standard for valve design criteria to maintain emergency access compliance.

Odorant Replacement Project

Natural Gas

Scope of Work

• Replaced aged odorant injection system, storage tank, containment, and building at gate station
• Decommissioned and remove existing and abandoned odorant systems and associated infrastructure
• Developed and install new odorant system including shelter, piping, controls, foundations, and electrical
• Coordinated full engineering lifecycle: design, demolition, procurement support, construction oversight, and commissioning
• Executed project within defined shut-in window to maintain system reliability and operational continuity

Deliverables

• Redlined piping and instrumentation diagrams, 3D model, isometric piping drawings, construction bill of material, and valve tie-in lists
• Civil, mechanical, structural, and electrical drawings
• Demolition drawing packages with mechanical, electrical, and instrumentation and controls scopes
• Procurement packages for tank, building, odorant system, and temporary odorization
• On-site construction support, contractor coordination, and commissioning oversight
• Final documentation including updated drawings, redlines, and closeout package

Project Highlights

• The project executed a full odorant system replacement within a limited five-month shut-in window, managing the demolition of two systems in parallel with the new installation to maintain site layout. The team proactively coordinated a temporary odorization option in case of commissioning delays, provided continuous oversight from initial design through construction and as-built documentation, and supported the development of long-term record drawings and standardized site files for future reuse.

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.

10,000 FT Medium Pressure Steel Main Replacement

Natural Gas Utilities

Scope of Work

• Completed design to replace 10,000 feet of medium-pressure steel main with polyethylene (PE) piping in an urban like corridor
• Coordination with both county and municipal jurisdictions for permitting and right-of-way
• Compliance-driven design schedule to support regulatory deadlines

Deliverables

• Detailed engineering and construction drawing package 
• Documentation – bill of materials, trenchless forms, pressure test forms, service orders, corrosion analysis, constructability review, environmental compliance plan
• Construction support – request for information responses, design updates, tie-in plan procedures and drawings, and permitting clarifications

Project Highlights

• The project encompassed a large scope within a dense, urban-like environment, requiring multi-jurisdictional permitting across city and county agencies. A tight compliance timeline necessitated expedited design and coordination.

Utilities and Internet Service Providers

Joint Use Make Ready Engineering

Scope of Work

• Regularly completes projects comprising of 5,000+ poles for new communication company attachments on electric utility owned poles
  • Including Route design, distribution design, and distribution construction
• Currently, completing a 24,000 pole (new fiber attachment) project including:
  • Field data collection
  • Make ready design
  • Incumbent local exchange carrier application submission
  • One touch make ready administration
  • Asset management work application updates
  • Construction package creation

Program Highlights

• Acquired 60 complex easements, including railroad and river crossings, for a communication company build out across Pennsylvania. Additionally, spearheading a one touch make ready program for both internet service provider’s and investor-owned utilities. Increasing upfront route decisions for the internet service provider and significantly reducing application processing time for the investor-owned utility.

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.

New 69kv-12.5kv Substation

Substation Engineering

Overview

• Location: Indiana
• Client: Midwest Investor-Owned Utility
• Timeline: Approximately 9 months

Scope

• Design civil and drainage plan for new substation
• Design new 69kv-12.5kv substation including the following major pieces of equipment:
• (2) 69kv incoming line load break disconnect switches
• (2) 69kv bus tie disconnect switches
• (2) 69kv circuit switchers for primary transformer protection
• (2) 69kv-12.5kv, 28mva transformers
• (1) 12.5kv switchgear building with (5) 12.5kv feeder circuits
• Design 12.5kv feeder cable/conduit runs to 1st pole outside of the substation
• Perform grounding study and design ground grid
• Prepare storm water pollution prevention plan (SWPPP) for project

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

161kV Transmission Line Rebuild

Transmission Line Engineering

Overview

• Location: Indiana
• Client: Midwest cooperative
• Timeline: 12 months

Scope

• Designed the rebuild of a 3-mile 69kV transmission line in PLS-CADD. The new line was designed to 161kV framing for future configurations
• Rerouted alignment in two locations to avoid river meandering and a house encroachment
• Project had three junctions with one-way and three-way switches
• Permitting, construction, and As-built support
• Plan and profile drawings, framing drawings, phasing drawings, stringing charts, staking tables, worklists, and material lists