Projects

Department Of Transportation (DOT) Project

Electric Distribution Engineering

Scope of Work

• Construction design for the relocation of existing 25kV sub-transmission and 15kV distribution overhead utilities to accommodate Department of Transportation (DOT) highway modifications and widening
• Coordinated with Department of Transportation (DOT) and other utilities for phased construction approach
• Facilitated and obtained private right of ways for new utility structures and easements
• Completed forestry efforts
• Designed demolition of existing facilities and distribution equipment
• Provided engineering support for highway rated underground utility designs

Deliverables

• Site visits to scope and assess constructability of relocations
• Produce a detailed design and construction package (cost estimate, design sheets, design maps, bill of material, circuit diagram, and material reservation using client work management application)
• Coordinate easement and permit research and secure permits with local and state jurisdiction
• Create and distribute construction packets
• Provide design support during construction

Project Highlights

• Orbital upheld all Department of Transportation (DOT) cost and schedule commitments throughout this multi-year effort, which began prior to 2020 and continued through COVID-era restrictions. When the utility partner faced internal resource limitations, Orbital stepped in to provide critical design and engineering support, keeping the project on track and maintaining construction momentum.

Product Storage and Transfer

Specialty Chemical

Scope of Work

• Project added two storage tanks, transfer pumps, load out structure with scales
• Orbital executed laser scanning and plant 3D model development of the new infrastructure in the existing facility
• Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting
• Supported local authority permit application and interfaces during design and construction phases

Deliverables

• Process design basis, PFDs and P&IDs
• Material requisition packages for tanks, pumps, agitators and filters
• Revised site plan
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Piling plan, 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, control narratives
• Scope of work documents for construction

Project Highlights

• New design added additional flexibility in facility operations in allowing for product loading at two separate truck areas and rail. Unloading capabilities and new raw material storage facilitated the ability to manufacture new product desired in market.
• Total Installed Cost (TIC) – $5MM

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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

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SRU Revamp

Oil and Gas

Scope of Work

• Developed FEED package with +/- 10% total installed cost estimate for a sulfur recovery unit revamp
• Project aimed to address constrained capacity, frequent faults and compliance gaps
• Orbital executed detailed design, start up and commissioning support for the project

Deliverables

• Process design basis, PFDs and P&IDs
• Material requisition packages for the new heater, boiler and tail gas treatment unit
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new equipment, piping and conduit
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for demolition and installation

Project Highlights

• 80% of the linear feet of installed piping was jacketed. Laser scanning accuracy and plant 3D modeling was critical to preventing field installation issues of the jacketed piping in the field.
• Total Installed Cost (TIC) – $12MM

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Turnkey Fireproofing and Structural Repairs of Mechanical Equipment

Specialty Chemical

Scope of Work:

• Executed a turnkey repair project for seven process vessels, providing services from inspection through repair and reinstatement
• Removed deteriorated intumescent and cementitious fireproofing from vessel column skirts and anchor bolt assemblies
• Performed abrasive blast cleaning to prepare vessel skirts for inspection and recoating
• Conducted detailed inspections, including visual assessments and ultrasonic thickness (UT) testing
• Evaluated corrosion damage using calipers and pit gauges
• Performed engineering evaluations to determine fitness for continued service
• Designed and implemented structural repairs to restore vessel integrity
• Completed final coating and reapplication of fireproofing

Deliverables:

• Inspection reports documenting visual findings and UT measurements
• Engineering evaluation and structural analysis
• Issued-For-Construction (IFC) drawings for anchor bolt replacement and base ring stiffener installation
• Completed structural repairs, including anchor bolt and stiffener installation
• Restored fireproofing and protective coating systems

Project Highlights:

• Orbital delivered a fully integrated turnkey repair solution for seven process vessels, seamlessly coordinating inspection, engineering, and field execution to minimize downtime and client oversight. Early identification of critical anchor bolt corrosion allowed Orbital to implement targeted structural repairs before further degradation could impact safety or operations. The project restored structural capacity and fire protection systems, extending the service life for each asset and improving long-term reliability. This effort highlights Orbital’s ability to deliver efficient, cost-effective repair solutions for critical infrastructure through a single, accountable team.

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34kV Breaker Replacement Program

Substation Engineering

Scope of Work

• Replace four 34kV circuit breakers
• Adaptation to re-use existing foundation
• Replace seven disconnect switches
• New cable trench
• Upgrade bus differential relaying and transformer relaying

Deliverables

• Detail design and construction package
  • Drawings – demolition, protection and control, physical, civil and structural
  • Review vendor drawings for breakers, disconnect switches, and cable trench
  • Material procurement support
• Construction support
• Incorporate as-built drawings post-construction

Project Highlights

• Orbital Engineering provided full engineering services for the breaker replacement program, including management of multiple sites, coordination of equipment ordering, and completion of required protection upgrades.

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Main Replacement Program – Class 4/5 Estimates

Natural Gas

Overview

• Location: Indiana
• Client: Midwest Investor-Owned Utility
• Timeline: 6 Months

Scope

• Reviewed four years of pipeline replacement plans totaling 240 miles
• Applied Class 4 estimates to 70 miles: Class 5 estimates to 170 miles
• Incorporated a 5% annual inflation factor
• Retirement estimates assumed in-place retirement except at aerial crossings
• Estimates included design, labor, material, construction costs, safety oversight, and restoration requirements
• Risk-ranked spreadsheet provided by client guided scope prioritization
• Preliminary design identified critical crossings and restoration areas

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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

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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

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