Sour Gas CTB-Facility Design
Oil & Gas | Upstream
Location | New Mexico
The Challenge
The client required a new centralized tank battery (CTB) in the Permian Basin capable of safely handling production from multiple wells with elevated hydrogen sulfide (H₂S) concentrations. The project demanded a design that would ensure compliance with all applicable NACE sour service standards while maintaining efficient operations and accommodating future development. Managing high H₂S levels—ranging from 1,000 to 2,400 ppm per well and averaging approximately 1,700 ppm across the CTB—posed significant challenges for material selection, corrosion protection, and overall process safety.
The Solution
Halker provided full engineering and design services for the new CTB, applying its extensive experience in sour gas management and NACE-compliant design. The facility incorporates advanced gas treatment technology, including a Streamline Valkyrie Unit designed to reduce H₂S outlet concentrations to 4 ppmv or less while operating efficiently at pressures from 90 to 180 psig. A throttle bypass pressure valve maintains stable operating pressures, and treated gas is routed to downstream processing facilities for final treatment.
Halker’s piping design strategically combined NACE-compliant and non-NACE specifications based on service conditions. High-pressure inlet, gas, and liquid outlet lines were constructed using NACE-compliant materials to mitigate sulfide stress cracking, while internally coated piping and corrosion-resistant materials such as ThermoFlex Plus and HDPE were used for water and gas lines to enhance long-term performance.
Flowlines were designed to align precisely with field wellhead locations, utilizing 4-inch, 750 psi-rated ThermoFlex Plus pipes with 100-foot casings beneath each drill pad for added protection. A 3-inch, Schedule 40 welded steel gas lift line supplies multiple pads, ensuring consistent gas management and operational flexibility.
By integrating robust sour gas treatment systems, corrosion-resistant materials, and rigorous compliance with NACE standards, Halker delivered a state-of-the-art facility that supports the client’s long-term production goals while maintaining the highest standards of safety, efficiency, and environmental responsibility.