Heavy Industrial

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

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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.

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Substation Relocation

Specialty Chemical

Scope of Work

• Existing client 34.5kV main substation was approaching the end of its useful life
• Orbital performed electrical and structural engineering to relocate the substation out of a central process area to eliminate overhead high voltage cable in the congested space
• Orbital subcontracted geotechnical and architectural services with trusted partners for a comprehensive offering

Deliverables

• SKM Model
• Revised site plan
• Single line diagrams, substation layouts, cable tray and conduit routing plans
• Foundation drawings, support details and cable tray bridge drawings
• Scope of work documents for construction

Project Highlights

• Project required interfacing with the utility to review impacts to the existing 34.5kV pole-mounted metering equipment and their upstream overhead distribution system. Orbital performed calculation comparison between the existing and new equipment to determine what incentives applied to the project for the client to pursue. Orbital led constructability planning sessions with client, Orbital and contractor to efficiently sequence the demolition and installation scopes.
• Total Installed Cost (TIC) – $10MM

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Water Intake Modification

Steel

Scope of Work

• Evaluate options for compliance with the EPA Clean Water Act section 316(b) for intake structures
• Upon option selection, executed engineering services for integrating the new solution into the existing 100-year-old pump house
• Orbital performed detailed engineering required to support construction of the new intake technology modifications and supported procurement activities through bid reviews, technical bid evaluations and vendor recommendations, vendor document review
• Orbital provided construction management onsite through the demolition and installation activities as well as provided review of contractor field submittals for shop steel detailing and concrete

Deliverables

• Material requisition packages for all equipment and bid packages for all contractors
• P6 schedule development for entire project through commissioning
• Site plan including underground piping and excavation
• Equipment mounting installation details
• Navisworks model, general arrangement drawings, piping plans, sections & elevations
• Foundation and steel drawings for supporting the new intake system, piping and electrical infrastructure
• Single line diagrams, power plans, MCC drawings, lighting plans, grounding plans, cable & conduit schedules, conduit routing plans, panelboard schedules
• Instrument datasheets, I/O list, instrument index, control system narrative, control system architecture drawing, wiring drawings
• Scope of work documents for demolition and construction

Project Highlights

• In review of regulations, Orbital proposed solution to establish compliance by lowering velocity rather than installing fish return which saved client approximately $13MM over originally conceived client options.
• Total Installed Cost (TIC) – $20MM

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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

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Mechanical Integrity (MI) Program Audit and Development

Specialty Chemical

Scope of Work:

• Performed a Mechanical Integrity (MI) audit following Department of Environmental Quality (DEQ) findings at a chemical manufacturing facility
• Conducted site walks and reviewed process documentation, including P&IDs, to identify assets requiring inclusion in an MI program
• Developed an MI asset registry, established inspection boundaries, highlighted P&IDs, and defined inspection intervals
• Built a fully compliant MI program aligned with OSHA Process Safety Management (PSM) requirements and 40 CFR 68.73
• Authored and approved extensive MI program documentation and procedures
• Developed asset-specific Inspection Test Plans (ITPs) addressing anticipated damage mechanisms and inspection requirements
• Executed baseline MI inspections using API-certified and NDT-certified inspectors
• Collected field data, photographs, inspection isometrics, and prepared detailed inspection reports
• Integrated all program documentation, inspection results, and reports into Orbital’s inspection database
• Provided ongoing MI program support, including inspections, NDT, corrosion expertise, and audit services

Deliverables:

• Mechanical Integrity audit findings and asset inventory
• MI asset registry with defined inspection boundaries and intervals
• Fully developed MI program compliant with OSHA PSM and DEQ requirements
• Over 35 approved MI program documents, including policies, procedures, checklists, and training materials
• Asset-specific Inspection Test Plans (ITPs)
• Baseline internal and external inspection reports with photographs and isometric drawings
• AutoCAD-developed inspection drawings and database-integrated records
• Ongoing inspection, NDT, and audit documentation

Project Highlights:

• Orbital developed and implemented a fully compliant Mechanical Integrity program for a chemical manufacturing facility following regulatory audit findings, providing a clear path to meeting OSHA PSM and DEQ requirements. Through a comprehensive audit and asset registry process, Orbital established a strong foundation that accounted for all applicable fixed equipment and defined clear inspection boundaries and intervals. By building the MI program from the ground up – including more than 35 tailored program documents and asset-specific Inspection Test Plans – Orbital delivered a robust, facility-specific solution aligned with regulatory standards. Baseline inspections performed by certified inspectors, combined with full database integration, positioned the client for streamlined compliance, efficient work management, and long-term program sustainability.

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Fire Water Pump Upgrades and Main Replacements

Oil and Gas

Scope of Work

• Executed multi-discipline engineering for a refinery-wide upgrade to the deteriorating firewater system
• Project objectives included:
  • Increased firefighting water supply capacity
  • Improved system pressure maintenance capabilities
  • Expansion of firewater pump control capabilities
  • Improved diesel engine cooling water filtration
  • Increased availability and maintainability of pumps

Deliverables

• Material requisition packages for new fire water pumps
• P&IDs and firewater maps
• Plot plans, general arrangement drawings, demolition drawings, piping orthographics, underground piping drawings, isometrics, pipe support details
• Foundation drawings, structural drawings
• Single line diagrams, panel drawings and schematics, cable and conduit schedules, conduit routing plans, underground duct bank plans and details, grounding plans, fiber routing plans, lighting plans
• Functional description, alarm list, instrument location plans, wiring diagrams, I/O list, instrument index, instrument datasheets, loop diagrams
• Scope of work documents for construction

Project Highlights

• The upgrade project was executed over a five-year period and design considerations throughout the project kept the existing firewater loop operational and limited downtime during the segment replacement process.
• Total Installed Cost (TIC) – $40MM

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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

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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.

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