Projects

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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Main Street Public Improvement Project

Natural Gas

Overview

• Location: Indiana
• Client: Midwest investor-owned utility
• Timeline: 4 Months

Scope

• Managed gas main conflicts associated with a 32-inch full pavement section, including HMA pavement, stone base, and chemically modified subgrade
• Addressed three key conflict areas, verified with Subsurface Utility Engineering (SUE) data:
  • Potential conflict with full pavement section depth
  • Direct conflict due to subgrade treatment and grade cut
  • Conflict with proposed storm pipe based on SUE data
• Turnkey project execution including:
  • Minimum three site visits
  • Packet creation and system documentation
  • Coordination with the utility coordinator for additional data
  • Comprehensive deliverables: IFC documents, bill of materials, tie-in procedure, trenchless technology form, pressure test forms, permits/easements, service orders, constructability review, corrosion recommendation, environmental compliance plan, and safety checklist

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Truck Scale Addition

Petrochemical

Scope of Work

• The primary goal of this project was to install a new truck scale and automation to improve operating costs reducing filling times and operator interfaces and provide an opportunity to load a separate product
• Orbital performed detailed engineering required to support construction of the new scale and automated system, procurement activities for securing components needed for the project, and field construction management activities

Deliverables

• Revised P&IDs and general arrangements
• Structural pipe supports drawings, access platform and hose manifold supports
• Scale pit design and drainage drawings, sidewalk and paving modification drawings
• Schematic wiring diagrams, and cable and conduit schedules
• Scope of work documents for construction

Project Highlights

• Project significantly reduced operator exposure and human factors through successful process automation.
• Total Installed Cost (TIC) – $8 MM

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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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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

 

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500kv Substation Line Terminal Upgrade

Substation Engineering

Overview

• Location: Pennsylvania
• Client: Northeastern Investor-Owned Utility
• Timeline: Approximately 12 months

Scope

• Replace 500kv breaker and associated disconnect switches
• Replace line drops and rigid bus for higher ampacity requirements
• Replace line relay panel with upgraded SEL’s for line monitoring and breaker failure

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Tank Farm Expansion

Petrochemical

SCOPE OF WORK

• Developed FEL-2 engineering and +/- 30% estimate for 30 new tanks and tank farm infrastructure
• Interfaced with tank vendor for required design modifications for EPA compliance
• Developed scopes of work and quantities for all disciplines and total installed cost estimate in Aspen Capital Cost Estimator

PROJECT HIGHLIGHTS

• Total installed cost estimate of $80MM
• Client awarded FEL-3 engineering as sole source and majority of detailed design to Orbital after successful FEL-2 execution.

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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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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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