See How We Deliver
From design through delivery, engineering the systems that support heavy industries and utilities since 1969.
Utilities
Department Of Transportation (DOT) Project
Electric Distribution Engineering
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.
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
Heavy Industrial
Storage and Truck Area Expansion
Oil and Gas
Storage and Truck Area Expansion
Oil and Gas
Scope of Work
- Orbital evaluated an existing tank storage structure to confirm the structure, and foundations could adequately support new tanks planned for the structure
- Evaluation showed that the existing footers were undersized, and the new tanks could not be safely added to the structure
- Recognizing the importance of the client’s expansion plans, Orbital prepared an alternate concept to support a subset of the tanks over the existing unloading bays and expand the unloading area for a third truck bay
- A stair tower was added to improve access to the tank support structure
Deliverables
- Navisworks model
- Foundation and paving modification drawings
- Structural steel drawings for tank storage and stair tower
- P&IDs and piping orthographics
- Scope of work documents for construction
Project Highlights
- The client’s expansion plans have continued uninterrupted due to the new design.
- Total Installed Cost (TIC) – $4MM
Asset Management
Orbital’s Role in Critical Structures Management Programs
Oil and Gas
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.
Heavy Industrial
Wastewater Treatment
Petrochemical
Wastewater Treatment
Petrochemical
Scope of Work
- Executed detailed design for a licensed technology provider integrating their wastewater treatment package into an existing client facility
- Orbital acted as engineer of record for the design required for the field construction packages
Deliverables
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting new equipment and pipe racks
- Single line diagrams, power plans, cable tray 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
- Orbital successfully interfaced with three local installation contractors for civil, mechanical, and E&I respectively, to support the licensed technology provider in delivering a successful turnkey offering to the client.
- Total Installed Cost (TIC) – $17MM
Heavy Industrial
Fuel Certainty
Power Generation
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
Heavy Industrial
Black Liquor Storage Tank
Specialty Chemical
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
Asset Management
Bridge Inspection and Turnkey Repairs
Power Generation
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.
Heavy Industrial
Substation Relocation
Specialty Chemical
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
