Projects

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

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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

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Water Crossing Evaluation

Natural Gas

Scope of Work

• Performed condition assessments of 374 pipeline stream crossings across Indiana and Kentucky
• Utilized Trimble DA2 GPS and Esri Field Maps for sub-centimeter accuracy and real-time GIS tracking
• Evaluated water crossing conditions including erosion, bank stability, and pipeline exposure
• Coordinated land access, scheduling, and communication across a wide geographic area
• Generated Corrective Action Plans (CAPs) and prioritization based on field observations

Deliverables

• Individual field reports with exposure, erosion, and integrity observations
• Risk ranking of 43 sites with noted issues
  • 3 Red: immediate action
  • 7 Orange: remediation recommended
  • 33 Yellow/none: monitoring recommended
• GIS dashboards and shapefiles with embedded condition data
• Sub-centimeter GPS data and photographic documentation per site
• Final report summarizing findings, lessons learned, and remediation recommendations

Project Highlights

• The project achieved 100% completion of 374 field sites within a six-month window and identified 13 new exposures along with multiple erosion and shallow-main risks. Throughout the work, the team maintained real-time communication and tracking through Esri and Trimble platforms, issued 31 CAPs to support immediate and planned remediation, and delivered geospatially enabled datasets and comprehensive documentation to support future asset planning.

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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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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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Fire Water Pump Upgrades and Main Replacements

Oil and Gas

Scope of Work

• Executed multi-discipline engineering for a refinery-wide upgrade to the deteriorating firewater system
• Project objectives included:
  • Increased firefighting water supply capacity
  • Improved system pressure maintenance capabilities
  • Expansion of firewater pump control capabilities
  • Improved diesel engine cooling water filtration
  • Increased availability and maintainability of pumps

Deliverables

• Material requisition packages for new fire water pumps
• P&IDs and firewater maps
• Plot plans, general arrangement drawings, demolition drawings, piping orthographics, underground piping drawings, isometrics, pipe support details
• Foundation drawings, structural drawings
• Single line diagrams, panel drawings and schematics, cable and conduit schedules, conduit routing plans, underground duct bank plans and details, grounding plans, fiber routing plans, lighting plans
• Functional description, alarm list, instrument location plans, wiring diagrams, I/O list, instrument index, instrument datasheets, loop diagrams
• Scope of work documents for construction

Project Highlights

• The upgrade project was executed over a five-year period and design considerations throughout the project kept the existing firewater loop operational and limited downtime during the segment replacement process.
• Total Installed Cost (TIC) – $40MM

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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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Glass Lined Reactor Additions

Specialty Chemical

Scope of Work

• The project modified an existing unit to accommodate the addition of three new glass lined reactors, numerous acid and caustic tanks
• A new bulk material handling and storage building was added along with a Redler material handling system to move the cohesive solids to the reactors
• Truck unloading for acid and caustic were installed and two new 750 HP boilers, water well and cooling tower were also added
• Approximately 4000 linear feet of product lines were run from the site to tie in at the adjacent plant
• 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 glass lined reactors, tanks, material handling systems, boilers and cooling tower
• Revised site plan
• Navisworks model, general arrangement drawings, piping plans and isometrics
• Foundation and steel drawings for supporting the new equipment and building
• Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, panelboard schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for construction

Project Highlights

• Entire project from award to completion was executed to a very aggressive schedule of 13 months.
• Total Installed Cost (TIC) – $15.8MM

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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

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