See How We Deliver
From design through delivery, engineering the systems that support industry and utilities since 1969.
Utilities
Programmatic Construction Oversight
Construction Management
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
Utilities
New Client Connections
Electric Distribution Engineering
New Client Connections
Electric Distribution Engineering
Scope of Work
- Construction design of a new overbuilt double 15kV circuit
- Designed new overhead extension dedicated for new customer while maintaining operation of underground services for surrounding industrial customers
- Completed demolition of existing underground facility services and distribution equipment
- Coordinated design with customer equipment, construction and in-service dates
Deliverables
- Site visits to scope and assess constructability of underground service
- Produce a detailed design and construction package (cost estimate, design sheets, design maps, bill of materials, circuit diagram, and material reservation using client work management application)
- Coordinate easement and permit research and secure permits with local & state jurisdiction
- Create and distribute construction packets to appropriate line shops
- Provide design support during construction
Project Highlights
- Successfully achieved customer cost commitments on a expedited schedule and provided critical support to our utility partner when internal design resources were unavailable to meet the project scope and schedule.
Asset Management
Orbital’s Role in Critical Structures Management Programs
Oil and Gas
Orbital’s Role in Critical Structures Management Programs
Oil and Gas
Scope of Work:
- Implemented and managed plantwide Critical Structures Management Programs for multiple clients
- Performed risk ranking and structural analysis across large, complex asset inventories
- Planned and executed inspection programs based on asset criticality and risk level
- Conducted routine and advanced inspections of process vessels, exchangers, buildings, foundations, stacks, and pipe racks
- Managed inspection data, prioritization, and repair recommendations within Orbital’s database
- Developed engineered repair solutions for assets requiring non-standard or complex repairs
- Supported execution and delivery of repairs to prevent recurrence of structural issues
Deliverables:
- Risk-ranked asset inventories and inspection schedules
- Inspection reports with prioritized findings and repair recommendations
- Database-driven tracking of inspection results and mitigation actions
- Engineered repair designs and analysis for complex structural conditions
- Ongoing program management documentation and reporting
Project Highlights:
- Orbital has provided long-term Critical Structures Management Program support for one of the world’s largest refineries, overseeing inspection and risk management activities for an asset inventory exceeding 15,000 structures. By assigning risk levels to each asset and aligning inspection frequency and level accordingly, Orbital established a systematic, defensible approach to managing structural integrity at scale. Inspection findings are captured, ranked, and tracked within Orbital’s database, allowing issues to be prioritized and addressed before they escalate. When standard repair solutions are not sufficient, Orbital’s engineering team delivers customized analyses and engineered repairs, helping clients proactively manage risk, reduce repeat issues, and maintain safe, reliable plant operations.
Asset Management
Bridge Inspection and Turnkey Repairs
Power Generation
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.
Utilities
138kV Substation Expansion
Substation Engineering
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.
Heavy Industrial
Feed Impurity Removal
Specialty Chemical
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
Featured
138kv System Reliability Project
Oil and Gas
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.
Heavy Industrial
Hot Oil Heater Replacement
Specialty Chemical
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
Featured
345k Double Breaker Interconnect Substation
Construction Management
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.
View More Projects
