Helium Plant Engineering & Design
Oil & Gas | Upstream
Location | Wyoming
The Challenge
The client required a full engineering and design solution for a new helium processing facility capable of handling complex gas treatment and extraction operations. The project demanded seamless coordination among multiple engineering disciplines and the successful integration of a third-party proprietary helium extraction system into the overall process. Achieving this required precise technical execution to ensure process safety, environmental compliance, and efficient system performance—while supporting the project from early concept through final commissioning.
The Solution
Halker provided comprehensive, multidisciplinary engineering and design services for the client’s helium plant, leading the project from conceptual development through punch list completion and final handoff of the operational facility. The team executed full-scope engineering across process, mechanical, civil/structural, and electrical, instrumentation, and controls (EI&C) disciplines, along with SCADA and automation programming.
The process design included an inlet separation system to handle wellhead gas, an amine treating system to remove hydrogen sulfide, and dehydration units to achieve the required gas moisture specifications prior to helium extraction. Halker worked closely with the third-party helium technology provider to integrate their proprietary system into the overall facility, ensuring smooth operational transitions and compliance with technical requirements. Downstream of the extraction system, Halker designed the handling and treatment of residual gas, routing it to a thermal oxidizer for safe and environmentally responsible disposal.
Throughout the three-year project, Halker maintained active collaboration with the client, providing engineering support from initial design through construction, commissioning, and operational readiness. The team developed a complete suite of deliverables—including PFDs, P&IDs, 3D models, structural and electrical packages, grounding and area classification plans, and a cause-and-effect matrix—to ensure design integrity and regulatory compliance.
By integrating complex third-party technology into a cohesive facility design and maintaining consistent coordination across all project phases, Halker delivered a fully functional, compliant, and efficient helium processing facility. This project demonstrated the team’s ability to execute highly technical, multi-discipline projects that meet the client’s operational, environmental, and business objectives.