Gas Plant Optimization Study
Oil & Gas | Midstream
Location | Colorado
The Challenge
The client required a comprehensive evaluation and process optimization effort to improve the accuracy of an existing gas processing plant model and identify opportunities for operational improvement. The existing process model contained outdated and incomplete information, limiting its reliability for performance analysis and decision-making. Additionally, discrepancies between plant hardware, control systems, and model assumptions created inefficiencies that impacted system optimization and overall productivity.
The Solution
Halker performed a detailed process evaluation combining off-site analysis with on-site investigation to enhance the accuracy and functionality of the plant’s process model. The team began by reviewing the client’s equipment documentation, extracting accurate data from legacy information to update the ProMax model prior to field activities. A multidisciplinary team—consisting of a Senior Process Engineer, a Mechanical Engineer, and a Controls Engineer—then conducted a site visit to perform equipment walkdowns, review control systems, interview operators, and identify data gaps affecting model accuracy.
Following the site visit, Halker refined the process model and performed case studies to evaluate plant limitations, assess potential process improvements, and quantify the benefits of proposed changes. Mechanical and controls observations were incorporated into a detailed report that provided actionable recommendations, short-term test plans, and strategies to validate the economic feasibility of long-term upgrades.
Through this targeted approach, Halker delivered a calibrated, reliable process model and a clear roadmap for operational and process optimization—empowering the client to enhance plant performance, improve efficiency, and guide future investment decisions.