Utility

10,000 FT Medium Pressure Steel Main Replacement

Natural Gas Utilities

Scope of Work

• Completed design to replace 10,000 feet of medium-pressure steel main with polyethylene (PE) piping in an urban like corridor
• Coordination with both county and municipal jurisdictions for permitting and right-of-way
• Compliance-driven design schedule to support regulatory deadlines

Deliverables

• Detailed engineering and construction drawing package 
• Documentation – bill of materials, trenchless forms, pressure test forms, service orders, corrosion analysis, constructability review, environmental compliance plan
• Construction support – request for information responses, design updates, tie-in plan procedures and drawings, and permitting clarifications

Project Highlights

• The project encompassed a large scope within a dense, urban-like environment, requiring multi-jurisdictional permitting across city and county agencies. A tight compliance timeline necessitated expedited design and coordination.

138kV Substation Expansion

Substation Engineering

Scope of Work:

• Completed design to interconnect new 25MW battery & 100MW solar facility to existing substation
• Expanded existing 138kV ring bus and add one new 138kV breaker position
• Required temporary configuration of existing 138kV line to facilitate construction
• Engineered two new monopoles and one H-frame to reconnect transmission line to expanded station
• New control building with new fiber connection to support protection and controls, and telecommunications

Deliverables:

• Detail design and construction package
  • Drawings – demolition, protection and control, physical, civil, transmission line with load trees
  • Studies – ground grid, foundations, substation structures, transmission line structures
  • Review vendor drawings for equipment, engineered structures, and calculations
• Construction support
• Incorporate as-built drawings post-construction

Project Highlights:

• Orbital Engineering navigated precise construction sequencing including temporary configurations to enable site build out while limiting downtime. Design included the relocation of existing transmission line to successfully expand the substation for the new solar and battery facility interconnection.

345k Double Breaker Interconnect Substation

Construction Management

Scope of Work:

• Managed project construction through all phases of the greenfield build including civil work, below grade (ground grid, foundations, cable trench), and above grade (H-frame and steel erection, equipment setting, bus install, inside wiring, and incoming line stringing) 
• Provided safety, environmental, and quality oversight

Deliverables:

• On-site safety audits
• Daily progress reports
• Schedule tracking and input
• Requests for Information
• Non-conformance reports
• Facilitation of material deliveries/returns
• Third-party contractor coordination
• Commissioning support

Project Highlights:

• The two-year project was delivered on budget and on schedule with strong stakeholder engagement throughout its lifecycle. With no safety incidents and multiple contractors involved across major construction phases, Orbital successfully navigated complex coordination and handoff challenges by applying deep technical expertise and maintaining strict alignment with owner processes and procedures.

Management Programs

Construction Management

Roles and Responsibilities

• Enforce stop work authority
• Hold construction crews accountable for compliance with owner safety processes
• Oversee execution of daily job safety briefings
• Ensure adherence to all site-specific safety and environmental plans
• Investigate and report on incidents
• Ensure required permits are maintained
• Support pre-construction planning, review drawings and bill of materials to avoid delays
• Oversee schedule performance and contribute to the development of schedule recovery plans
• Monitor construction quality by verifying compliance with drawings and specifications and preparing non-conformance reports
• Facilitate the request for information process
• Coordinate material and equipment deliveries
• Manage material inventory
• Support subcontractor assignments
• Maintain organized project records such as redlines, photos, and equipment data for final turnover at project closeout

Program Highlights

• Orbital supports investor-owned utilities throughout the country with dedicated teams of construction managers and quality management professionals. With nearly 100 boots-on-the-ground resources, Orbital’s construction management teams play a critical role in the safe and successful execution of more than $750MM in construction work annually. Through robust onboarding and continuous education programs, Orbital’s teams have the capability to support a variety of projects including new build substations, substation equipment upgrades, new build overhead transmission and distribution lines, grid modernization, underground cable replacement, overhead and underground fiber builds, and communications structure erection.

Inlet/Outlet Valve Evaluation

Natural Gas

Scope of Work

• Performed GIS and records-based analysis of 1,617 gas regulating stations
• Evaluated compliance with inlet/outlet critical valve design standards
• Validated valve data from GIS and Maximo using spatial analysis and attribution logic
• Assigned station risk ratings based on valve presence, type, and quantity
• Developed formal reclassification, design, and investigation workflows for 1,100+ non-compliant stations
• Recommended future valve placement or conversion to critical designation using industry standards

Deliverables

• Executive summary and class 5 capital planning estimate
• G.A.C.-coded dataset with risk priority assignments 
• Planning template outlining time estimates by station priority level
• Engineering design trigger list for non-compliant or undocumented stations
• Reclassification workflow diagram and phase 3 execution guidance
• GIS shapefiles for pipelines, stations, valves, and analysis overlays
• Maximo/GIS data cleanup recommendations and asset tracking integration

Project Highlights

• The team analyzed 1,617 stations across the service territory, finding that approximately 32% were compliant, 44% required formal design, and 24% were convertible through reclassification. They introduced a desktop validation and G.A.C. priority framework to streamline program actions, supported program execution with valve planning templates and phase 3 task sequencing, and applied the client’s gas standard for valve design criteria to maintain emergency access compliance.

Odorant Replacement Project

Natural Gas

Scope of Work

• Replaced aged odorant injection system, storage tank, containment, and building at gate station
• Decommissioned and remove existing and abandoned odorant systems and associated infrastructure
• Developed and install new odorant system including shelter, piping, controls, foundations, and electrical
• Coordinated full engineering lifecycle: design, demolition, procurement support, construction oversight, and commissioning
• Executed project within defined shut-in window to maintain system reliability and operational continuity

Deliverables

• Redlined piping and instrumentation diagrams, 3D model, isometric piping drawings, construction bill of material, and valve tie-in lists
• Civil, mechanical, structural, and electrical drawings
• Demolition drawing packages with mechanical, electrical, and instrumentation and controls scopes
• Procurement packages for tank, building, odorant system, and temporary odorization
• On-site construction support, contractor coordination, and commissioning oversight
• Final documentation including updated drawings, redlines, and closeout package

Project Highlights

• The project executed a full odorant system replacement within a limited five-month shut-in window, managing the demolition of two systems in parallel with the new installation to maintain site layout. The team proactively coordinated a temporary odorization option in case of commissioning delays, provided continuous oversight from initial design through construction and as-built documentation, and supported the development of long-term record drawings and standardized site files for future reuse.

Federal Funded Maintenance Program Management

Natural Gas

Scope of Work

• Lead multi-year remediation program targeting pipeline crossings, attachments, station coatings, and vehicular protection
• Developed and manage program execution for both distribution and transmission assets
• Coordinated engineering design, field documentation, and construction oversight
• Implemented phased strategy to address incomplete records, stakeholder coordination, and environmental constraints
• Updated scope to reflect evolving regulatory standards and risk assessments

Deliverables

• Engineering design packages for crossings, coatings, and protection devices
• Document control system for tracking as-builts, construction status, and compliance
• Quality assurance and quality control oversight during construction with daily/weekly field documentation
• Program tracking tools for budget, schedule, and asset-level progress
• Stakeholder communication framework to support utility, municipal, and contractor coordination
• Lessons learned and continuous improvement reports

Project Highlights

• The project successfully remediated all 23 targeted sites, and in 2024 the program expanded to include additional station coating and vehicular protection scope. The initiative supports the long-term goal of remediating over 800 assets by 2026, with an adaptable framework that accommodates evolving scope and shifting regulatory focus, providing full lifecycle support from design through construction, quality assurance, quality control, and final documentation.

Main Street Public Improvement Project

Natural Gas

Overview

• Location: Indiana
• Client: Midwest investor-owned utility
• Timeline: 4 Months

Scope

• Managed gas main conflicts associated with a 32-inch full pavement section, including HMA pavement, stone base, and chemically modified subgrade
• Addressed three key conflict areas, verified with Subsurface Utility Engineering (SUE) data:
  • Potential conflict with full pavement section depth
  • Direct conflict due to subgrade treatment and grade cut
  • Conflict with proposed storm pipe based on SUE data
• Turnkey project execution including:
  • Minimum three site visits
  • Packet creation and system documentation
  • Coordination with the utility coordinator for additional data
  • Comprehensive deliverables: IFC documents, bill of materials, tie-in procedure, trenchless technology form, pressure test forms, permits/easements, service orders, constructability review, corrosion recommendation, environmental compliance plan, and safety checklist

69kV Transmission Line Extension

Transmission Line Engineering

Scope of Work

• Completed design to extend a 69kV line 15-miles to a new substation
• Designed 400 new steel direct embed poles supporting 477 ACSR and OPGW static
• Executed two new steel engineered poles on foundations for railroad crossing
• Existing distribution assets were designed to be transferred onto the new steel poles
• Completed four one-way switching structures at tie-in junctions

Deliverables

• Preliminary design, detailed design and construction package
• Drawings – plan and profile, framing drawings, bill of materials, drilling details, engineered pole loading tree drawings, foundation drawings, easement drawings, tree clearing drawings
• Studies – PLS-CADD model, monopole structure analysis, stringing, shielding protection
• Review vendor drawings for engineered poles, equipment, and drilling locations
• Construction and permitting support
• Incorporate as-built drawings post-construction

GIS Support

• Subsurface utility engineering level D utility locates were enhanced by digitizing both above-ground and below-ground infrastructure
• Developed a GIS web application that visualizes the entire 15-mile corridor
• The app integrated 2D mapping and 3D LiDAR survey data to improve cross-team collaboration, increase data transparency, and support more informed decision-making throughout the project lifecycle

138kv Substation Modification To Accommodate New Generation Tie Line

Substation Engineering

Overview

• Location: Indiana
• Client: Midwest investor-owned utility
• Timeline: 12 Months

Scope

• Design expansion of existing substation yard to the west
• Design expansion of existing 138kv ring bus to the west. add new 138kv breaker position
• Design new 138kv h-frame structure to accommodate the new incoming 138kv line
• Design transmission line interconnection from first pole outside of the substation to the new h-frame
• Perform grounding study and design grounding improvements for the substation
• Design new control building to house new relay and metering panels
• Design fiber interconnection with existing communications system

345kV Ring Bus Substation

Substation Engineering

Scope of Work

• Completed design for greenfield 345kV substation with six-position ring bus configuration
• Controlled building layout including wall elevations, vendor coordination, and drawing review

Deliverables

• Fully engineered design and construction package including civil structural, physical, and protection and control
• Transmission line loading
• Studies – ground grid, lighting, and lightning
• Review vendor drawings for equipment
• Construction support
• Incorporate as-built drawings post-construction

Project Highlights

• Orbital Engineering completed the full greenfield design, coordinating with client engineers for foundation placement and sizing, communication interfaces, and security, and guided equipment vendors to ensure all equipment integrated into the design for proper performance and compliance with governing codes and standards.

Programmatic Construction Oversight

Construction Management

Overview

• Location: Indiana
• Client: Midwest investor-owned utility
• Timeline: Annual program

Scope

• Safety and Environmental:
  • Enact Stop Work Authority and hold all site personnel accountable for Owner’s System Safety Process.
  • Participate in the development of and enforce daily site JSA’s (Job Safety Analysis).
  • Report on safety and environmental incidents via the Owner standard process.
  • Ensure adherence to site specific safety plans and environmental compliance plans.
  • Track permitting to be sure appropriate permits are in place and time frames are observed.
• Planning and Schedule Monitoring:
  • Support pre-construction efforts to ensure projects are completed safely, efficiently, and economically.
  • Review drawings and BOM’s prior to start of construction to avoid delays associated with material / personnel.
  • Report on status of scheduled activities (behind, ahead, percent complete, anticipated complete date, etc.)
  • Participate in development of schedule recovery plans when necessary.
• Quality Assurance:
  • Ensure that projects are constructed according to engineering drawings and applicable specifications.
  • Develop and submit RFI’s and NCR’s (Non-Conformance Reports).
  • Vendor, Sub-Contractor and Supplier Interface.
  • Coordinate deliveries and returns of construction material and equipment.
  • Keep inventory of materials and identify field material needs in an effort to avoid project delays.
  • Support coordination of subcontractor assignments.
• Record Keeping:
  • Ensure all redlines, photos, and equipment data (model, serial numbers, etc.) are organized for turnover at project completion.

Orbital’s Construction Management Teams have managed projects of all types, such as:

• New build substations (Hinshaw Interconnect Substation)
• New build overhead transmission and distribution
• Switchgear and transformer replacement
• Pole, structure, and overhead conductor replacement (Trans. Monopole Exchange)
• Underground cable replacement
• New fiber installations and fiber replacement
• Communications tower erection