Heavy Industrial Projects
See how Orbital supports heavy industrial facilities in developing projects, executing work, and managing essential industrial assets.
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
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.
Coal Delivery System Modification
Power Generation
Scope of Work
- Coal fired power generation facility client faced a dilemma with their existing barge unloader only capable of unloading barges up to a specific width, limiting the type of barge that can be used in delivery
- Further complicating the delivery, the barges that fit within the constraints of the unloader are becoming less available due to age
- Orbital developed conceptual solution for a new barge unloading system that allowed for unloading jumbo barges to the existing surge bin via deck mounted Sennebogen cranes, hoppers and conveyors on a new deck barges and incline conveyors to the existing surge bin
- Once approved, Orbital executed detailed design including procurement support in equipment specification and selection, owner’s engineering and construction support
Deliverables
- General arrangement drawings and total installed cost estimates for various solutions
- Material requisition packages for conveyors and hoppers
- Conveyor support steel drawings and foundations
- Single line diagrams, power plans, lighting plans, grounding plans, cable & conduit schedules
- Scope of work documents for construction
Project Highlights
- Project was originally deemed an “unsolvable problem” due to complexities in the design interfaces, contractual interfaces between delivery and client and limited remaining operating window for the facility. Orbital’s efficient solution allowed for the project to be authorized, and the facility is currently conducting coal unloading operations via the new unloading system. The facility operating permit has been extended since project completion making the solution benefits realized well into the future.
- Total Installed Cost (TIC) – $4MM
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 Program for Power Generation Client
Power Generation
Scope of Work:
- Reviewed and developed corporate inspection procedures and standards for a Power Generation client
- Collaborated with client stakeholders to align documentation with industry standards and practical, field-validated inspection methodologies
- Established inspection criteria for plant structures
- Developed and introduced a new “Ready-to-Fall” risk assessment methodology to evaluate potential structural and attachment failures
- Supported post-acquisition integration by creating a phased implementation plan for newly acquired facilities to align with the corporate inspection program
Deliverables:
- Updated corporate inspection procedures and standards documentation
- “Ready-to-Fall” risk assessment framework, including:
- Visual condition rating criteria
- Risk scoring based on likelihood and severity
- Mitigation timelines to guide maintenance actions
- Phased implementation plan to support onboarding of newly acquired facilities into the corporate inspection program
Project Highlights:
- Orbital strengthened the client’s structural integrity program by pairing field-validated inspection procedures with a quantitative, risk-based methodology for managing degradation and fall hazards. The introduction of the “Ready-to-Fall” assessment model provided clear, defensible prioritization for stabilization, barricading, and repair actions across the client’s fleet. These improvements led to a measurable reduction in safety incidents related to structural failures and improved regulatory compliance across all facilities. Orbital’s approach elevated inspection practices from reactive evaluations to a proactive, data-driven strategy supporting safer, more reliable plant operations.
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
