Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
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.
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
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
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
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.
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.
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.
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.
Hot Oil Heater Replacement
Specialty Chemical
Scope of Work
- Executed FEL-3 engineering and detailed design for a hot oil heater replacement
- Project aimed to reduce fuel consumption by replacing an oversized hot oil-fired heater with a smaller, more efficient unit
- The replacement unit would still burn natural gas and fuel oil with incremental reductions in greenhouse gas emissions
- During the FEL stages, an alternate ethanol fired hot oil heater was investigated with the facility using spent ethanol as the primary fuel for the burner instead of natural gas and fuel oil
- Orbital performed conceptual design for integrating both options complete with total installed cost estimate for each option. Owner decided to proceed with the ethanol fired heater option
- Orbital supported construction activities through bid walks with each field contractor, responding to inquiries during bid clarifications, evaluating bids and providing recommendation on contractor for award
- Orbital performed construction management during key construction activities
Deliverables
- Process design basis and P&IDs
- Material requisition packages for hot oil heater and ancillary equipment (pumps, tanks, filters)
- Navisworks model, 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
- Scope of work documents for construction
Project Highlights
- The ethanol fired option, while more expensive, allowed the facility to reduce their greenhouse emissions by 50% making significant impact on their sustainability goals.
- Total Installed Cost (TIC) – $4MM
Glass Lined Reactor Additions
Specialty Chemical
Scope of Work
- The project modified an existing unit to accommodate the addition of three new glass lined reactors, numerous acid and caustic tanks
- A new bulk material handling and storage building was added along with a Redler material handling system to move the cohesive solids to the reactors
- Truck unloading for acid and caustic were installed and two new 750 HP boilers, water well and cooling tower were also added
- Approximately 4000 linear feet of product lines were run from the site to tie in at the adjacent plant
- 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 glass lined reactors, tanks, material handling systems, boilers and cooling tower
- Revised site plan
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting the new equipment and building
- 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 construction
Project Highlights
- Entire project from award to completion was executed to a very aggressive schedule of 13 months.
- Total Installed Cost (TIC) – $15.8MM
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
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
Crude Storage Tank
Oil and Gas
Scope of Work
- Execution of FEL-2, FEL-3 and detailed design. Total installed cost estimates and project schedules supported Owner gate approvals at each stage
- Project added 325,000 BBL tank, pumps, heaters, mixers, firewater/foam system, MOV’s, VFD’s and High Mast Lighting
- Orbital executed multi-discipline engineering for all disciplines
Deliverables
- Process design basis, PFDs and P&IDs
- Material requisition packages for tanks, pumps and other equipment
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting the new tanks, pumps, piping and electrical infrastructure
- Single line diagrams, power plans, duct bank and cable tray plans, lighting plans, grounding plans, cable and conduit schedules, panelboard schedules
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for construction
Project Highlights
- Pipeline pumps, connections and controls were made to tie this scope into a tank farms 35 miles away.
- Total Installed Cost (TIC) – $25MM
SRU Revamp
Oil and Gas
Scope of Work
- Developed FEED package with +/- 10% total installed cost estimate for a sulfur recovery unit revamp
- Project aimed to address constrained capacity, frequent faults and compliance gaps
- Orbital executed detailed design, start up and commissioning support for the project
Deliverables
- Process design basis, PFDs and P&IDs
- Material requisition packages for the new heater, boiler and tail gas treatment unit
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting the new equipment, piping and conduit
- Instrument location plans, wiring diagrams, loop diagrams, instrument datasheets
- Scope of work documents for demolition and installation
Project Highlights
- 80% of the linear feet of installed piping was jacketed. Laser scanning accuracy and plant 3D modeling was critical to preventing field installation issues of the jacketed piping in the field.
- Total Installed Cost (TIC) – $12MM
