Bulk Test Conversion for Sour Service CTB Facility

Oil & Gas    |    Upstream

Location     |    New Mexico

The Challenge

The client required the conversion of existing Central Tank Battery (CTB) facilities into a large-scale sour service production site capable of safely managing high hydrogen sulfide (H₂S) concentrations. The project demanded a comprehensive redesign to accommodate new process equipment, integrate sour gas treatment systems, and ensure full compliance with applicable safety and regulatory standards. This effort required adapting previously standardized designs to meet the unique challenges of sour service operations, while maintaining constructability, efficiency, and cost control.

The Solution

Halker provided full multidisciplinary engineering and design services to transform the existing CTB facilities into a high-capacity, sour service operation. The design incorporated new inlet and test separator skids, heater treaters, vapor recovery systems, H₂S treatment units, oil and water tanks, flare systems, sales gas metering, and gas lift compression systems. Electrical and instrumentation components—including power distribution, PLC controls, and wellhead remote I/O panels—were integrated to ensure reliable monitoring and control of all process systems.

Key engineering contributions included:

  • Process Engineering: Conducted detailed process simulations using Schlumberger’s VMG Symmetry software and supported a full Process Hazard Analysis (PHA) to verify safety and operability.
  • Mechanical and Piping Engineering: Developed mechanical calculations and equipment BOMs, produced a detailed 3D model of the facility, and refined piping and module designs through multiple review stages.
  • Civil/Structural Engineering: Designed shallow foundations, drilled piers, and modular steel supports consistent with prior facility standards.
  • Electrical and Instrumentation (EI&C): Applied proven design standards for power distribution and control systems, ensuring compliance with PHA outcomes and overall system safety.

 

By leveraging lessons learned from previous projects and adapting them for sour service conditions, Halker delivered a complete, constructible, and regulatory-compliant design package. The final solution maximized operational safety and reliability while providing the client with a flexible, efficient facility designed for long-term performance.