Midstream Plant Expansion
Oil & Gas | Midstream
Location | Utah
The Challenge
The client required comprehensive engineering and design support to execute a series of upgrades at an existing natural gas processing facility. The project involved integrating new compression and heating systems into an established plant layout while maintaining operational continuity and meeting modern safety, electrical, and structural standards. Key challenges included equipment selection and placement within tight spatial constraints, coordination of multidisciplinary design updates, and ensuring compliance with process safety and code requirements under an accelerated schedule.
The Solution
Halker provided full multidisciplinary engineering support across process, mechanical, piping, civil, structural, electrical, and instrumentation disciplines to deliver a cohesive and fully integrated design solution. The team oversaw equipment sizing, data sheet development, and bid reviews for major new equipment, including a 3-stage inlet gas compressor and a dual screw propane compressor, both located at the end of the existing pipe rack. Additional scope included evaluating propane condenser options, replacing the existing TEG heater and surge drum with a natural gas-fired hot oil/TEG heater, and designing a new Deethanizer reboiler system to improve plant efficiency and reliability.
Halker updated facility plot plans, P&IDs, and 3D piping models, conducting multiple site visits to perform as-built verification and participate in Process Hazard Analyses (PHAs) and action item closeouts. The team also performed a detailed ventilation study in accordance with API RP 500 to confirm electrical classification and building ventilation requirements.
Civil and structural engineers developed grading, drainage, and trenching plans and designed equipment supports, foundations, and platforms compliant with IBC 2018 standards. Mechanical and piping teams produced layouts, piping plans, material specifications, and line lists, while the electrical and instrumentation group provided load studies, MCC modifications, heat trace design, I/O lists, and control panel documentation.
Procurement support included bill of materials development and bid evaluations for engineered equipment, ensuring technical alignment with vendor designs. Weekly coordination meetings and progress updates maintained alignment with the client’s objectives, allowing Halker to deliver a safe, efficient, and fully operable facility upgrade that met all performance, safety, and schedule requirements.