Heavy Industrial

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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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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Mechanical Integrity (MI) Program Audit and Development

Specialty Chemical

Scope of Work:

• Performed a Mechanical Integrity (MI) audit following Department of Environmental Quality (DEQ) findings at a chemical manufacturing facility
• Conducted site walks and reviewed process documentation, including P&IDs, to identify assets requiring inclusion in an MI program
• Developed an MI asset registry, established inspection boundaries, highlighted P&IDs, and defined inspection intervals
• Built a fully compliant MI program aligned with OSHA Process Safety Management (PSM) requirements and 40 CFR 68.73
• Authored and approved extensive MI program documentation and procedures
• Developed asset-specific Inspection Test Plans (ITPs) addressing anticipated damage mechanisms and inspection requirements
• Executed baseline MI inspections using API-certified and NDT-certified inspectors
• Collected field data, photographs, inspection isometrics, and prepared detailed inspection reports
• Integrated all program documentation, inspection results, and reports into Orbital’s inspection database
• Provided ongoing MI program support, including inspections, NDT, corrosion expertise, and audit services

Deliverables:

• Mechanical Integrity audit findings and asset inventory
• MI asset registry with defined inspection boundaries and intervals
• Fully developed MI program compliant with OSHA PSM and DEQ requirements
• Over 35 approved MI program documents, including policies, procedures, checklists, and training materials
• Asset-specific Inspection Test Plans (ITPs)
• Baseline internal and external inspection reports with photographs and isometric drawings
• AutoCAD-developed inspection drawings and database-integrated records
• Ongoing inspection, NDT, and audit documentation

Project Highlights:

• Orbital developed and implemented a fully compliant Mechanical Integrity program for a chemical manufacturing facility following regulatory audit findings, providing a clear path to meeting OSHA PSM and DEQ requirements. Through a comprehensive audit and asset registry process, Orbital established a strong foundation that accounted for all applicable fixed equipment and defined clear inspection boundaries and intervals. By building the MI program from the ground up – including more than 35 tailored program documents and asset-specific Inspection Test Plans – Orbital delivered a robust, facility-specific solution aligned with regulatory standards. Baseline inspections performed by certified inspectors, combined with full database integration, positioned the client for streamlined compliance, efficient work management, and long-term program sustainability.

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Railroad Loading Stations

Specialty Chemical

Scope of Work

• Project added six new sulfuric acid railcar loading stations to the existing chemical facility
• The additional stations and gangways were added along with new piping, pumps and instrumentation for facility operations

Deliverables

• Navisworks model, general arrangement drawings, piping plans and isometrics
• Steel drawings for extension of the existing loading area and moveable gangways to accommodate railcars of different sizes
• Single line diagrams, power plans, conduit plans, lighting plans, grounding plans, cable and conduit schedules
• Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
• Scope of work documents for installation

Project Highlights

• Railcar logistics drastically reduced costs over existing tanker transport means.
• Total Installed Cost (TIC) – $8MM

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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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Asset Management Program for a Steel Mill Client

Steel

Scope of Work:

• Supported a major steel client in the development and ongoing evolution of their corporate asset management program
• Provided technical assistance in creating the original corporate inspection procedure and supporting subsequent revisions
• Applied decades of hands-on inspection experience across structural and mechanical assets at domestic and international facilities
• Defined and refined inspection and reporting processes used across the client’s enterprise
• Coordinated and supported field inspection operations to align with corporate standards and safety requirements
• Integrated emerging technologies and digital tools to enhance inspection efficiency and data management

Deliverables:

• Corporate inspection procedures and revisions
• Digital inspection data outputs supporting asset tracking and long-term program management
• Standardized inspection and reporting frameworks, including:
  • Defined inspection levels
  • Standard reporting formats
  • Means and methods documents for individual assets
  • Documentation protocols
    • Boundary documents

Project Highlights:

• Orbital played a foundational role in building and evolving the client’s corporate asset management program, applying decades of inspection experience to create practical, safety-focused procedures adopted company-wide. Standardized inspection levels, reporting formats, and documentation protocols improved consistency and reliability across domestic and international operations. Through ongoing inspection programs and the integration of advanced technologies such as UAS inspections and digital data management, Orbital continues to drive continuous improvement. This long-term collaboration has helped modernize inspection practices while supporting OSHA/ANSI compliance and the client’s reliability-centered maintenance objectives.

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Emergency Response Support – Critical Failure

Steel

Scope of Work:

• Responded to an emergency inspection request following a critical failure at the Pipe Bridge end panel connection
• Performed on-site damage assessment after debris accumulation led to moisture intrusion, deterioration, and structural failure
• Deployed an emergency response team to collect field data and evaluate the condition of the truss system
• Analyzed structural distress across the Pipe Bridge, including overstressed members and failed connections
• Designed temporary shoring and permanent repair solutions
• Provided construction-phase engineering support through restoration and return to service

Deliverables:

• Emergency inspection and condition assessment findings
• Structural calculations evaluating end reactions and overstressed members
• Temporary field support and shoring designs
• Detailed repair packages for permanent restoration
• Construction support and oversight documentation

Project Highlights:

• Orbital’s rapid emergency response following a critical Pipe Bridge failure minimized risk and accelerated recovery for a facility experiencing prolonged operational disruption. The team assessed extensive structural distress within a 384-foot truss system, identifying hundreds of overstressed members and extreme end reactions approaching one million pounds. By quickly designing temporary support systems and permanent repairs, Orbital restored structural integrity and returned the Pipe Bridge to service. The successful execution of complex field repairs, including extensive welding and construction oversight, demonstrated Orbital’s ability to manage high-risk structural failures under demanding conditions.

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OH-Crane, Crane Runway and Building Inspection

Steel

Scope of Work:

• Performed a comprehensive technical inspection of an industrial building, crane runway system, and overhead bridge crane at a major manufacturing facility
• Verified structural integrity of building framing and crane runway support systems
• Assessed condition and alignment of crane rails, runway beams, and associated structural components
• Conducted a full OSHA/ASME-compliant overhead crane inspection during a single coordinated site mobilization
• Deployed a multidisciplinary team of structural inspectors, scanning technicians, and certified overhead crane specialists
• Utilized aerial lifts, top-side runway access, and Elios 3 caged drone technology for difficult-to-access areas
• Performed alignment verification using Total Station surveying methods
• Applied visual, hands-on, and targeted non-destructive testing (NDT) techniques
• Executed mechanical, structural, electrical, and functional testing of overhead crane components
• Provided real-time notification of critical or out-of-service safety findings

Deliverables:

• Structural inspection findings for building framing and crane runway systems
• OSHA/ASME-compliant overhead crane inspection report
• Runway alignment measurements, including elevation, sweep, span, and cross-levelness data
• Severity-ranked deficiency listings with tagged photographs and measurement documentation
• Conceptual repair sketches for identified structural and runway deficiencies
• Preventive maintenance, repair, and long-term monitoring recommendations
• Integrated inspection report capturing all findings from a single mobilization

Project Highlights:

• Orbital delivered a fully integrated, multi-discipline inspection of an industrial building, crane runway, and overhead crane system in a single site mobilization, minimizing operational disruption and eliminating the need for multiple specialty contractors. By combining structural inspection, advanced scanning, precision alignment verification, and OSHA/ASME-compliant crane evaluation, Orbital provided a complete system-level assessment of both structural and mechanical performance. The inspection identified runway alignment deviations, localized structural corrosion, and typical crane component wear, allowing Orbital’s engineering team to develop prioritized repair recommendations and conceptual solutions. This project highlights Orbital’s ability to deliver efficient, technically rigorous inspection programs that support safe, reliable crane operations in complex industrial environments.

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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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