Projects

Buried Regulator Program Evaluation

Natural Gas

Scope of Work

• Evaluated 3,300 buried gas regulators across a regional network
• Developed cost-efficient remediation strategies based on risk and infrastructure proximity
• Assessed replacement options, including mainline extensions and above-grade designs
• Benchmarked project costs using historical construction data
• Built geospatial tools to identify regional clusters and prioritize replacements
• Created installation guidelines using a data-driven breakeven distance threshold

Deliverables

• Engineering assessment report including:
  • Cost comparisons for above-grade vs. below-grade remediation methods
  • Risk evaluation and compliance considerations
  • Capital project analysis of 27 replacement efforts
• GIS-based proximity analysis and cluster modeling to guide future planning
• Prioritization tool using spreadsheet, dashboard, and geospatial integration
• Replacement decision-making framework incorporating breakeven cost thresholds
• Tracking enhancements to align asset records across engineering and mapping systems

Project Highlights

• The project produced a utility-wide remediation model for buried gas regulators, defining per-regulator cost drivers and a breakeven point for choosing between regulator replacement and main extensions. Orbital analyzed multiple design alternatives to standardize future installations and enable strategic, program-wide planning through GIS, engineering analytics, and stakeholder input.

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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.

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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

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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.

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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.

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

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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.

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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.

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New Robotic Machine

Steel

Scope of Work

• Coordinated with client and vendor for installation of innovative robotic system that flames away all surface defects from the face, sides, edges, and corners of the slab, of any length, width, thickness or deflection to meet the mill’s total conditioning requirements
• Primary process equipment for the project includes scarfer, slab turner, and transfer cars
• Orbital provided multi-discipline engineering and design services for the installation deliverables to support construction of the facility

Deliverables

• Site plan including tie-ins to sanitary sewer and underground drainpipes
• Navisworks model, general arrangement drawings, piping plans, sections & elevations
• Equipment, trough, trench, foundation, debris and water pits, sump concrete drawings
• Structural steel access platforms and supports for ductwork, piping, tray and conduit
• Structural steel drawings for five monorail cranes; one for robot removal and one over each rail for rail removal/replacement
• Single line diagrams, power plans, MCC drawings, lighting plans, grounding plans, cable & conduit schedules, conduit routing plans, panelboard schedules
• Scope of work documents for construction

Project Highlights

• The system was installed within an existing mill building and separately enclosed for fume and dust control.
• Total Installed Cost (TIC) – $10MM

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