Process Engineering Projects

Precision in Every Flow

Oil and gas production site with storage vessels, process equipment, and monitoring infrastructure, highlighting Halker’s expertise in OOOOc compliance walkdowns, regulatory assessments, and emissions-reduction solutions for upstream facilities.

OOOOc Compliance Walkdowns

The client required a comprehensive assessment of over 80 production facilities to evaluate compliance with proposed EPA 40 CFR 60

Engineering schematic showing pipeline routing, valve configurations, and meter sites for a multi-site midstream tie-in, highlighting Halker’s expertise in pipeline design, system integration, and optimized flow management across complex gathering networks.

Multi-Site Midstream Tie In Project

The client required a comprehensive engineering and design solution for a complex, multi-site pipeline tie-in project involving several interconnected valve

Midstream natural gas processing equipment with insulated piping, filter vessels, and structural supports in an outdoor facility, showcasing Halker’s operational efficiency upgrades focused on optimizing throughput, reducing bottlenecks, and improving reliability in midstream plant operations.

Midstream Plant Operational Efficiency Upgrades

The client required critical piping and equipment modifications to improve operational efficiency and system reliability within an existing process unit.

Natural gas meter skid with flow measurement equipment, process piping, valves, and support structures installed on a concrete foundation, highlighting Halker’s expertise in precision metering, tie-in engineering, and midstream facility integration.

Meter Skid Tie In Project

The client required a detailed engineering and design solution to integrate multiple new meter skids—a main meter skid, a buy-back

3D process model of a helium plant showing multicolored piping, pressure vessels, and equipment layouts, illustrating Halker’s expertise in process simulation, facility optimization, and engineering design for helium recovery and midstream gas processing.

Helium Plant Process Study

A client required a detailed process engineering study to evaluate the technical and economic feasibility of developing a new helium

3D model of a Central Tank Battery (CTB) facility layout featuring tanks, separators, pipe racks, and wellpad tie-ins, showcasing Halker’s expertise in Permian Basin facility design, production optimization, and standardized upstream engineering programs.

Permian Basin CTB-Facility Design Program

The client required a multi-facility program to design and construct a series of centralized tank batteries (CTBs) to serve multiple

3D model of a Bakken Basin central tank battery (CTB) facility layout featuring tanks, piping networks, and process equipment, showcasing Halker’s expertise in upstream facility engineering, multidisciplinary design, and programmatic development for high-efficiency oil and gas production sites.

Bakken Basin CTB Facility Design Program

The client required an Owner’s Engineer to support the design and implementation of new centralized tank battery (CTB) facilities in

3D engineering model of an oil and gas processing facility with tanks, vertical process vessels, pump skids, and multicolored piping, illustrating Halker’s comprehensive upstream facility design, equipment layout optimization, and multidisciplinary engineering capabilities.

CTB-Facility Design Program

The client required detailed engineering and design for multiple centralized tank battery (CTB) and well pad facilities in New Mexico.

3D engineering model of a Salt Water Disposal (SWD) facility showing aligned storage tanks, piping networks, and equipment skids, highlighting Halker’s expertise in SWD system design, facility optimization, and produced-water management engineering.

SWD Engineering and Design

The client required a comprehensive engineering and design solution for a new saltwater disposal (SWD) facility that aligned with established

Large above-ground SWD storage tanks labeled TANK 5110 and TANK 5120 with access stairways and safety railings, showcasing Halker’s expertise in Salt Water Disposal commissioning, construction support, and facility startup operations.

SWD Commissioning and Construction Support

The client required comprehensive commissioning and startup support for a newly constructed saltwater disposal (SWD) facility. The project assumed mechanical

A Permian Basin oil and gas production site with interconnected piping, storage vessels, and equipment laid out across a gravel pad, illustrating Halker’s expertise in OOOOb regulatory compliance walkdowns, emissions assessment, and facility readiness verification.

Permian Basin OOOOb Compliance Walk Downs

The client required accurate and verifiable greenhouse gas (GHG) emissions data for existing facilities across the Permian Basin. Many sites

Midstream natural gas processing facility with pressure vessels, heat exchangers, structural pipe racks, and interconnected process piping, showcasing Halker’s engineering capabilities in midstream plant expansions, system optimization, and brownfield infrastructure upgrades.

Midstream Plant Expansion

The client required comprehensive engineering and design support to execute a series of upgrades at an existing natural gas processing

Aerial view of a remote helium processing plant with modular equipment skids, separators, compressors, and process piping arranged on a cleared desert site, highlighting Halker’s expertise in helium plant engineering, facility design, and specialty gas processing infrastructure.

Helium Plant Engineering & Design

The client required a full engineering and design solution for a new helium processing facility capable of handling complex gas

Natural gas processing facility with tall distillation towers, interconnected process piping, and equipment platforms, illustrating Halker’s expertise in gas plant optimization, throughput improvement, and operational efficiency engineering.

Gas Plant Optimization Study

The client required a comprehensive evaluation and process optimization effort to improve the accuracy of an existing gas processing plant

Engineering site assessment data table detailing gas, hydrocarbon liquid, and wellstream compositions, highlighting Halker’s expertise in production analysis, facility evaluation, and data-driven engineering recommendations for oil and gas operations.

Engineering Site Assessments

The client required detailed engineering assessments for twenty well pad facilities in the Permian Basin to verify compliance with federal

3D engineering model of a high-capacity 10,000–20,000 BBLPD saltwater disposal (SWD) facility featuring multiple storage tanks, piping networks, and process equipment, showcasing Halker’s expertise in produced water infrastructure design, system optimization, and large-scale midstream project engineering.

10,000-20,000 BBLPD SWD Engineering and Design

The client required a fully integrated engineering and design solution for a new 10,000 BBLPD saltwater disposal (SWD) facility, with

3D model of a greenfield compressor station featuring dual compressor units, process piping, and structural supports, highlighting Halker’s engineering and design expertise in midstream infrastructure, equipment layout optimization, and new-build natural gas compression facilities.

Greenfield Compressor Station Engineering and Design

The client required full engineering, design, and project management support for the development of a new greenfield gas gathering compressor

3D process model showing vertical vessel conversions with integrated piping and instrumentation, demonstrating Halker’s engineering expertise in bulk test modifications for sour service CTB facilities and compliance-driven upgrades to handle H₂S-rich production streams safely and efficiently.

Bulk Test Conversion for Sour Service CTB Facility

The client required the conversion of existing Central Tank Battery (CTB) facilities into a large-scale sour service production site capable

Salt Water Disposal (SWD) facility featuring horizontal pressure vessels, tank batteries, and interconnected process piping, showcasing Halker’s engineering and infrastructure expertise in produced water handling, treatment, and reliable midstream disposal system design.

Salt Water Disposal Facility & Infrastructure

Halker was tasked with coordinating the design of the Water Gathering Infrastructure with the contractors responsible for the Oil &

Process flow diagram for a sour gas central tank battery (CTB) facility, illustrating separators, scrubbers, H₂S treatment, chemical injection systems, and flare routing, emphasizing Halker’s expertise in designing safe, compliant, and efficient sour-service production facilities.

Sour Gas CTB-Facility Design

The client required a new centralized tank battery (CTB) in the Permian Basin capable of safely handling production from multiple

Water Injection

A Halker Client was in need of water injection facilities that could meet the needs of their water flood at

Process flow diagram illustrating a mercury removal system with interconnected piping, vessels, and control instrumentation, emphasizing Halker’s process engineering capabilities in contaminant mitigation, system optimization, and compliant facility design.

Mercury Removal & Bonus Target

In 2020, a Midstream distribution company (“Client”), with nearly 10,000 miles of pipelines and over 50 terminals for refined petroleum

Bulk woodchip biomass being loaded into a transport trailer at an industrial facility, highlighting Halker’s renewable energy engineering expertise in biomass handling, waste-to-fuel conversion, and sustainable jet fuel production processes.

Conversion of Biomass Waste to Jet Fuel

Our client owns a process to convert carbon containing feedstock into syngas. This specific technology was selected for application at

2D piping model with highlighted red lines showing emission pathways between storage tanks, illustrating Halker’s expertise in conducting detailed fugitive emissions studies for regulatory compliance and operational risk reduction.

Fugitive Emissions Study

The client needed to reduce or eliminate fugitive emissions from over 50 existing upstream production facilities in order to meet

Oilfield wellhead assembly with valves and piping in the foreground and a field technician conducting site evaluation in the background, highlighting Halker’s expertise in full-field development planning, production optimization, and comprehensive upstream facility engineering.

Full-Field Development

Process Engineering, Project Engineering, Equipment Design, Civil/Structural Design, Electrical Design, Instrumentation Design

Digital hydraulic model with color-coded pipeline segments and contour lines illustrating pressure and flow behavior across a complex network, demonstrating Halker’s expertise in fluid dynamics analysis, pipeline optimization, and advanced hydraulic modeling for energy infrastructure.

Hydraulic Modeling Study

The client requested hydraulic modeling and simulation of existing gas and water pipeline networks in order to assess wellhead pressures

3D model of a multi-tank oil and gas gathering facility with detailed piping networks and equipment layouts, showcasing Halker’s expertise in pipeline hydraulics, gathering system design, and comprehensive pipeflow modeling for optimized production performance.

Gathering and Pipeflow Modeling

A Texas based company looked to longtime partner Halker Consulting, to create a flow model of the design for an

Engineers in hard hats observing an active flare stack at a midstream facility, emphasizing Halker’s expertise in flare system analysis, emissions management, and safety-focused flare study evaluations for oil and gas operations.

Flare Study Project

As federal regulations continue to change and become more stringent, Oil and Gas companies must conform to these guidelines in

Field engineer observing an active flare stack alongside compressors and process equipment at a midstream facility, highlighting Halker’s expertise in flare system retrofits, combustion safety improvements, and emissions-compliant facility upgrades.

Flare System Retrofit

In 2015, a publicly traded pipeline transport company (“Client”), approached Halker Consulting (“Halker”) to evaluate a recently acquired gas plant.

$Detailed mechanical and process engineering drawing of a frac tower return-to-service scope, showcasing Halker’s expertise in equipment evaluation, piping design, and safe reintegration of critical oil and gas production systems.$

Frac Tower Return to Service

In 2015, a Midstream distribution company (“Client”), with terminals spanning across the United States, approached Halker
Consulting LLC (“Halker”)

Gas Compressor Station

As with many Halker customers, this Texas based organization was challenged with a lack of internal engineering resources to match

Three Phase Separator

This experienced customer came to Halker Consulting with a need to design and engineer a three phase separator for multiple

Midstream facility with interconnected process piping, tanks, and equipment set against a wide-open landscape, highlighting Halker’s expertise in facilities conversion, system upgrades, and engineering solutions tailored to evolving operational needs.

Facilities Conversion to Meet Evolving Needs

Maybe they were not producing enough oil and gas previously to justify the infrastructure investment, or maybe the wells in

Large oil and gas production facility with storage tanks, process equipment, and a centralized operations trailer set against open field terrain, showcasing Halker’s strategic field development expertise in planning, designing, and optimizing multi-well production sites for efficient and scalable operations.

Strategic Field Development

The widespread adoption of offshore-born approaches by surface well operators in the last several years has been game changing for

Central Processing Facilities

As the American oil and gas industry moves away from single-well, vertical drilling techniques and embraces the opportunities available via

Multi-well pad facility with rows of wellhead assemblies, flowlines, valves, and manifolds arranged on elevated steel supports, showcasing Halker’s engineering expertise in designing high-density upstream production sites optimized for reliability, flow management, and efficient field development.

Multi-Well Site Facilities

The paradigm of American energy is undergoing a massive transformation. In addition to the evolution of renewable energy technologies, and