Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
Heavy Industrial
Reactor Heating Process Improvement
Specialty Chemical
Reactor Heating Process Improvement
Specialty Chemical
Scope of Work
- Orbital performed process evaluations and cost estimating for several solutions to add a new heating source to an existing reactor to allow for additional product formulation
- Following completion of FEL-2, Orbital proposed a turnkey offering for the new heat exchanger and auxiliary system upgrades to achieve the project objectives
- Orbital acted as prime for the EPC project with a mutually trusted field contractor for the client
Deliverables
- Process Design Basis and P&IDs
- Material requisition package for the new heat exchanger
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and exchanger support structure steel drawings for supporting the new heat exchanger
- Scope of work documents for installation
Project Highlights
- Installation and commissioning were completed in 10 days due to thorough constructability planning and pre-outage construction activities.
- Total Installed Cost (TIC) – $5MM
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
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
Featured
Blast Furnace Gas Main Replacement
Steel
Blast Furnace Gas Main Replacement
Steel
Scope of Work
- Design blast furnace gas main replacement
- Supported project from early stages of existing facility documentation research, infrastructure inspection and utility investigation through flow modeling, detailed design and construction management
- Led shutdown planning following review of existing isolation (valves, blinds) and design incorporation of new isolation where required
Deliverables
- Flow model for confirmation of gas main sizing
- Goggle valve replacement packages including design drawings, sections, details and scope of work
- Inspection reports, standard repair details and engineering repair and replacement drawings, where required
Project Highlights
- Project showcased the uniqueness of Orbital with full-service asset integrity investigation and engineering solutions from one firm.
- Total Installed Cost (TIC) – $25MM
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
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
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
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
Heavy Industrial
Electrical Substation Upgrades
Oil and Gas
Electrical Substation Upgrades
Oil and Gas
Scope of Work
- Executed FEL-2 engineering through detailed design and construction support for a new substation
- Project included demolition of an existing electrical building, 34.5kV to 13.8kV transformers and 13.8kV switch gear and replacement with two new 34.5kV to 13.8kV transformers and 15kV gas insulated switchgear as well as the addition of two 13.8kV to 4.160kV transformers, two 13.8kV to 480V transformers, 5kV arc resistant switchgear, 5kV arc resistant MCCs, and 480V MCCs
- Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting
Deliverables
- Material requisition packages for major electrical equipment – transformers, switchgear, MCC’s, non-segregated electrical bus duct, neutral grounding resistors, station batteries and battery chargers, electrical equipment building
- Single line diagrams, cable schedules, building layouts, transformer yard layouts and elevations, underground duct bank plan and sections, grounding plan, lighting plan
- Building demolition plan, foundation and underground utility demolition plan, site plans, foundation plans and sections, pipe bridge plans and sections for new steel and existing steel modifications
- Scope of work documents for construction
Project Highlights
- The project was part of a 10-year facility electrical upgrades plan developed by Orbital for the site. The complete 10-year planning effort included identification of turnaround windows, schedules and budget forecasting for completing four substation projects over the duration.
- Total Installed Cost (TIC) – $26MM
