Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
Heavy Industrial
Truck Scale Addition
Petrochemical
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
Asset Management
Mechanical Integrity (MI) Program Audit and Development
Specialty Chemical
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.
Featured
138kv System Reliability Project
Oil and Gas
138kv System Reliability Project
Oil and Gas
Scope of Work
- Option evaluation to improve reliability of the existing 138 kV ring buses as recent incidents disrupted operations at the facility
- Objective of the first phase of the project was to select a viable solution to increase reliability to prevent similar disruptions in the future
Deliverables
- Reliability risk identification report with conceptual solutions
- For each proposed option:
- One-line diagrams
- General arrangement drawings
- Total installed cost estimates
Project Highlights
- Project was jointly executed between Orbital’s Utility and Heavy Industrial division to interface with Utility and client for one team execution in review of client risk areas and proposal of design modifications. Capabilities on both sides of the Utility connection allowed for single firm consultation reducing client need to contract to and facilitate information exchange between multiple firms.
Asset Management
API 653 Tank Inspection and Floor Replacement
Specialty Chemical
API 653 Tank Inspection and Floor Replacement
Specialty Chemical
Scope of Work:
- Performed an out-of-service API 653 tank inspection, including a Magnetic Flux Leakage (MFL) floor scan
- Evaluated tank floor condition and investigated MFL indications using ultrasonic thickness testing (UTT)
- Documented and marked areas approaching T-minimum for repair
- Developed API 653–compliant engineering designs for complete tank floor replacement
- Designed modifications to accommodate relocation of multiple tank shell nozzles
- Defined non-destructive examination (NDE) requirements associated with repairs
- Provided on-site quality assurance and quality control oversight throughout all phases of construction and repair
- Verified completion and documentation of all corrective actions
- Prepared and issued final inspection documentation confirming fitness for service
Deliverables:
- API 653 out-of-service inspection report
- MFL floor scan results and UTT verification data
- Detailed API 653–compliant repair drawings for full floor replacement
- NDE procedures and inspection requirements
- Quality assurance and quality control oversight documentation and repair verification records
- Final inspection report confirming safe, compliant return to service
Project Highlights:
- Orbital executed a comprehensive API 653 inspection and major repair program for a 99,500-gallon storage tank, identifying floor corrosion risks through advanced MFL scanning and targeted ultrasonic testing. Early detection of low-thickness areas approaching T-minimum allowed Orbital to design proactive repairs before loss of containment could occur. The project required complete tank floor replacement and the relocation of multiple shell nozzles – complex modifications successfully delivered through Orbital’s integrated inspection, engineering, and quality assurance and quality control oversight. The repairs restored the tank to a safe, compliant operating condition, extended its remaining service life, and reduced the client’s risk of unplanned outages and future repair costs.
Heavy Industrial
Water Intake Modification
Steel
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
Featured
Natural Gas Processing
Natural Gas
Natural Gas Processing
Natural Gas
Scope of Work
- Demolition of existing natural gas storage well metering and withdrawal dehydration systems at two adjacent sites, reconfiguration of existing system at one of the sites and tie-in of all wells to new dehydration, metering and pressure regulation
- In addition to multi-discipline engineering for all disciplines, Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor document reviews
Deliverables
- Process Design Basis, PFDs and P&IDs,
- Revised Site Plan incorporating changes for storm water runoff and drainage, fencing and landscaping
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting the new equipment and buildings
- Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, lightning protection design, panelboard schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for demolition and installation
Projects Highlights
- Orbital adapted to client request to change dehydration technology early in the project and dehydration location mid-project due to permitting constraints with minimum impacts to overall schedule. All dehydration, metering, pressure regulation and waste stream storage and transfer was housed in a single Operations building.
- Total Installed Cost (TIC) – $10MM
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
Gum Treatment Project
Specialty Chemical
Gum Treatment Project
Specialty Chemical
Scope of Work
- This project included the installation of a new 40 ft tall retention tanks, 4 plate and frame exchangers, 25 ft tall feed tanks and centrifuge within multi-level process structure, cooling tower, inline mechanical shear mixer, clean-in-place (CIP) system (pump, tank, and controls), air purge system, multiple pumps (centrifugal and PD), and piping
- 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 all process equipment
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting new equipment, piping and cable tray
- Single line diagrams, power plans, cable tray plans, lighting plans, grounding plans, cable and conduit schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Spooling and prefabricated steel allowed above grade construction to be completed during a fast-track turnaround of 14 days.
- Total Installed Cost (TIC) – $6MM
Asset Management
Emergency Response Support – Critical Failure
Steel
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.
