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
SRU Revamp
Oil and Gas
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
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
Black Liquor Storage Tank
Specialty Chemical
Black Liquor Storage Tank
Specialty Chemical
Scope of Work
- Project included facility addition of a field fabricated tank, pumps, rake and new MCC building
- Orbital executed detailed design and supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review and delivery expediting
Deliverables
- Material requisition packages for tank, pump and new MCC building housing new electrical equipment
- Revised site plan
- Navisworks model, general arrangement drawings, piping plans and isometrics
- Foundation and steel drawings for supporting the new tanks, piping and cable tray
- Single line diagrams, power plans, cable tray plans, lighting plans, grounding plans, cable and conduit schedules
- Scope of work documents for construction
Project Highlights
- Alternate foundation design proposed in the early FEL stages of the project resulted in savings of over $500,000 to the client.
- Total Installed Cost (TIC) – $12MM
Asset Management
OH-Crane, Crane Runway and Building Inspection
Steel
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.
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
Asset Management
Turnkey Fireproofing and Structural Repairs of Mechanical Equipment
Specialty Chemical
Turnkey Fireproofing and Structural Repairs of Mechanical Equipment
Specialty Chemical
Scope of Work:
- Executed a turnkey repair project for seven process vessels, providing services from inspection through repair and reinstatement
- Removed deteriorated intumescent and cementitious fireproofing from vessel column skirts and anchor bolt assemblies
- Performed abrasive blast cleaning to prepare vessel skirts for inspection and recoating
- Conducted detailed inspections, including visual assessments and ultrasonic thickness (UT) testing
- Evaluated corrosion damage using calipers and pit gauges
- Performed engineering evaluations to determine fitness for continued service
- Designed and implemented structural repairs to restore vessel integrity
- Completed final coating and reapplication of fireproofing
Deliverables:
- Inspection reports documenting visual findings and UT measurements
- Engineering evaluation and structural analysis
- Issued-For-Construction (IFC) drawings for anchor bolt replacement and base ring stiffener installation
- Completed structural repairs, including anchor bolt and stiffener installation
- Restored fireproofing and protective coating systems
Project Highlights:
- Orbital delivered a fully integrated turnkey repair solution for seven process vessels, seamlessly coordinating inspection, engineering, and field execution to minimize downtime and client oversight. Early identification of critical anchor bolt corrosion allowed Orbital to implement targeted structural repairs before further degradation could impact safety or operations. The project restored structural capacity and fire protection systems, extending the service life for each asset and improving long-term reliability. This effort highlights Orbital’s ability to deliver efficient, cost-effective repair solutions for critical infrastructure through a single, accountable team.
Asset Management
Asset Management Program for a Steel Mill Client
Steel
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.
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
