Utility

34kV Breaker Replacement Program

Substation Engineering

Scope of Work

• Replace four 34kV circuit breakers
• Adaptation to re-use existing foundation
• Replace seven disconnect switches
• New cable trench
• Upgrade bus differential relaying and transformer relaying

Deliverables

• Detail design and construction package
  • Drawings – demolition, protection and control, physical, civil and structural
  • Review vendor drawings for breakers, disconnect switches, and cable trench
  • Material procurement support
• Construction support
• Incorporate as-built drawings post-construction

Project Highlights

• Orbital Engineering provided full engineering services for the breaker replacement program, including management of multiple sites, coordination of equipment ordering, and completion of required protection upgrades.

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.

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.

Double Wood Mitigation Program

Double Wood Program Managment

Overview

• Location: Nationally
• Client: Multiple 
• Timeline: Annual Program

Scope

• Manage all facets of the client’s double wood program for their electric service territory in support of infrastructure improvement and joint-use projects.
• Scouting
  • Orbital team documents all double wood locations in a specified geography by identifying unknown/undocumented locations and field verifying known locations.
• Field Data Collection
  • Orbital team collects all relevant data for pole including location coordinates, pole number, configuration, attachment types and owners, constructability notes, pre-construction photos, etc.
  • Orbital conducts on-site evaluation of the need for power make-ready using handheld laser range finders to verify that making transfers will not result in NESC Violation.
• Double Wood Mitigation
  
  • Orbital team communicates transfer requests to third party attachment owners through utility’s preferred notification system (NJUNS, SPANS, etc.) and enforces contracts up to and including support of billing third party attachment owners for late transfers.
  • Orbital utilizes qualified subcontracted partner to mitigate double wood locations by transferring any remaining attachments, removing the double pole, and completing restoration (backfill, seed, concrete, etc.)
• Orbital utilizes its proprietary GIS web-based Double Wood Dashboard to manage data related to client’s double wood program.
  • Utility stakeholders are provided access to the dashboard which enables near real-time monitoring of workflow progression for individual poles with photos provided at each construction step.
  • All double wood locations are color coded in map view based on current workflow step to support prioritization/resource planning efforts. 
  • Filters, charts, and tables are available in the tool to allow for various levels of progress reporting.

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

Department Of Transportation (DOT) Project

Electric Distribution Engineering

Scope of Work

• Construction design for the relocation of existing 25kV sub-transmission and 15kV distribution overhead utilities to accommodate Department of Transportation (DOT) highway modifications and widening
• Coordinated with Department of Transportation (DOT) and other utilities for phased construction approach
• Facilitated and obtained private right of ways for new utility structures and easements
• Completed forestry efforts
• Designed demolition of existing facilities and distribution equipment
• Provided engineering support for highway rated underground utility designs

Deliverables

• Site visits to scope and assess constructability of relocations
• Produce a detailed design and construction package (cost estimate, design sheets, design maps, bill of material, circuit diagram, and material reservation using client work management application)
• Coordinate easement and permit research and secure permits with local and state jurisdiction
• Create and distribute construction packets
• Provide design support during construction

Project Highlights

• Orbital upheld all Department of Transportation (DOT) cost and schedule commitments throughout this multi-year effort, which began prior to 2020 and continued through COVID-era restrictions. When the utility partner faced internal resource limitations, Orbital stepped in to provide critical design and engineering support, keeping the project on track and maintaining construction momentum.

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

New 69kv-12.5kv Substation

Substation Engineering

Overview

• Location: Indiana
• Client: Midwest Investor-Owned Utility
• Timeline: Approximately 9 months

Scope

• Design civil and drainage plan for new substation
• Design new 69kv-12.5kv substation including the following major pieces of equipment:
• (2) 69kv incoming line load break disconnect switches
• (2) 69kv bus tie disconnect switches
• (2) 69kv circuit switchers for primary transformer protection
• (2) 69kv-12.5kv, 28mva transformers
• (1) 12.5kv switchgear building with (5) 12.5kv feeder circuits
• Design 12.5kv feeder cable/conduit runs to 1st pole outside of the substation
• Perform grounding study and design ground grid
• Prepare storm water pollution prevention plan (SWPPP) for project