Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
Asset Management
Bridge Inspection and Turnkey Repairs
Power Generation
Bridge Inspection and Turnkey Repairs
Power Generation
Scope of Work:
- Performed a comprehensive inspection of a ~1,000-foot suspension bridge spanning a major waterway
- Utilized ground-based, elevated walkway, and rope-access techniques to evaluate hard-to-reach areas
- Benchmarked findings against prior inspection reports to identify changes and new deficiencies
- Classified deficiencies by priority level to guide repair urgency and scope
- Performed engineering analysis and developed Standard Repair Procedures (SRPs) for identified deficiencies
- Coordinated access constraints, including railroad scheduling, live powerline limitations, and follow-up inspections
- Executed turnkey repair construction for the north half of the bridge, including demolition and repairs
- Provided construction coordination, safety planning, and on-site quality oversight
Deliverables:
- Phased inspection reports as segments of the bridge were completed
- A repair prioritization ranking assigned to each finding
- Standard Repair Procedures (SRPs) and engineering repair IFC drawings for Priority 1 deficiencies
- Construction coordination and quality assurance documentation
- Final inspection report and repair verification records
Project Highlights:
- Orbital delivered a comprehensive inspection and turnkey repair program for a 1,000-foot suspension bridge, combining rope-access inspection, structural engineering, and construction oversight to address complex access and safety challenges. The inspection identified 43 deficiencies, including multiple Priority 1 conditions such as widespread cracked welds, severe section loss in a primary truss chord, and extensive concrete spalling with exposed reinforcement. Orbital executed phased reporting to support timely decision-making and completed full demolition and repairs on the north half of the bridge. When lead-containing coatings were discovered mid-demolition, Orbital paused work, coordinated with regulatory agencies, and implemented a revised, compliant construction plan – allowing repairs to resume and conclude efficiently while maintaining safety, regulatory compliance, and structural integrity.
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
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
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
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
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
Product Storage and Transfer
Specialty Chemical
Product Storage and Transfer
Specialty Chemical
Scope of Work
- Project added two storage tanks, transfer pumps, load out structure with scales
- Orbital executed laser scanning and plant 3D model development of the new infrastructure in the existing facility
- Orbital supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting
- Supported local authority permit application and interfaces during design and construction phases
Deliverables
- Process design basis, PFDs and P&IDs
- Material requisition packages for tanks, pumps, agitators and filters
- Revised site plan
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Piling plan, 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, control narratives
- Scope of work documents for construction
Project Highlights
- New design added additional flexibility in facility operations in allowing for product loading at two separate truck areas and rail. Unloading capabilities and new raw material storage facilitated the ability to manufacture new product desired in market.
- Total Installed Cost (TIC) – $5MM
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
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.
