Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
Heavy Industrial
New Robotic Machine
Steel
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
Heavy Industrial
Large Terminal Expansion
Oil and Gas
Large Terminal Expansion
Oil and Gas
Scope of Work
- Increase tank storage and distribution at the existing terminal
- Project added twelve 150,000 BBL storage tanks, one 15,000 BBL transmix tank, six transfer pumps with a combined maximum capacity of 55,000 BPH, one blending pump and two stripping pumps
- Orbital executed multi-discipline engineering for all disciplines including subcontract of geotechnical services and stormwater management with trusted partners
- Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting
Deliverables
- Process design basis, PFDs and P&IDs
- Material requisition packages for tanks and pumps
- 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 tanks, pumps, piping and electrical infrastructure
- Civil design deliverables for 200’x50’x25’ deep outbound manifold pit, 175’x50’ inbound wing manifold and grading / paving modifications at the terminal
- 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 demolition and installation
Project Highlights
- Expansion increased the Terminal ability to handle external demands for multiple product grades and larger volumes as well as supported internal stakeholder desires for greater flexibility in meeting seasonal demand and market fluctuations.
- Total Installed Cost (TIC) – $200MM
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
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
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.
Heavy Industrial
Chemical Plant
Specialty Chemical
Chemical Plant
Specialty Chemical
Scope of Work
- Project included the installation of two new reactors into an existing enclosed facility
- Laser scanning was conducted to collect field data for the 10-level existing facility
- One new reactor was tied into the existing DCS system with the other reactor expected to be tied in at a later date
Deliverables
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Steel drawings for supporting the new reactors, piping and conduit
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Laser scan data supported constructability reviews and definition of demolition needed to lower the 2 new reactors through the roof and down to level 3.
- Total Installed Cost (TIC) – $3.2MM
Heavy Industrial
Feed Impurity Removal
Specialty Chemical
Feed Impurity Removal
Specialty Chemical
Scope of Work
- The objective of this project was to remove the oil and grease from the incoming feed flow that is utilized throughout the plant’s operations
- With these impurities being removed prior to the feed entering the Strippers, it improved the efficiency of the production at the site
- Project included installation of two oil storage tanks and six pumps with containment with all interconnecting piping, steel and supports
- A raised MCC structure on piles and a concrete pad supported transformer was added to the east of the main project area to supply power for the project and a new Delta V Cabinet with HMI was located in the new MCC building
- The existing truck parking was relocated to the northeast along with connecting existing roadways to allow for a different exit path
- New surveillance cameras were integrated with an existing camera network located at gate to the East of the proposed parking location
- Full electrical scope included adding a 13.8kV feeder, 13.8kV/480V transformer, substation building, 480V motor control center, VFD’s, UPS, panels, control stations, lighting, grounding, and associated cable tray/conduit and cables
Deliverables
- Revised site plan
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Piping, foundation and steel drawings for supporting new tanks, pumps, MCC, transformer and piping
- Grading plans, sections and details for new roadway and parking lot
- Material requisition packages for major electrical equipment – 13.8kV switch, 13.8kV to 480V transformer, substation building, 480V MCC, UPS System
- Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable & conduit schedules, area classification drawings
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets, control narratives
- Scope of work documents for construction
Project Highlights
- Maintenance work was minimized significantly as a result of the project, decreasing downtime while increasing productivity.
- Total Installed Cost (TIC) – $120MM
Heavy Industrial
Fire Water Pump Upgrades and Main Replacements
Oil and Gas
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
Heavy Industrial
Railroad Loading Stations
Specialty Chemical
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
