A tank battery is an essential upstream oil and gas facility consisting of a group of interconnected tanks and equipment used to store, separate, and treat raw hydrocarbons. Tank batteries help separate oil, gas, and water through mechanical and chemical processes.
This page covers the full scope of tank batteries oil and gas design, construction, and installation services for oil and gas operators and project managers. Whether you are developing a new field, expanding existing production, or upgrading for compliance, understanding tank batteries oil and gas is critical for efficient, safe, and compliant operations.
Tank batteries are critical infrastructure in the energy industry and oil and gas industry, handling not only oil and natural gas but also other products such as asphalt, paraffin, and petroleum byproducts. These integrated systems receive, separate, treat, and store produced fluids from your wells—turning raw well output into sales-ready crude oil and properly managed produced water.
The overall tank battery consists of an integrated system of storage tanks, processing equipment, flow lines, and auxiliary components, all working together to support oil and gas industry operations. The composition of a tank battery will change and evolve over the life of the well, adapting to shifts in production and the types of fluids being managed.
Understanding the interior layout of a vessel, as well as its place in the overall tank battery, is vital for efficient and safe operations.
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A tank battery is an essential upstream oil and gas facility consisting of a group of interconnected tanks and equipment used to store, separate, and treat raw hydrocarbons. Tank batteries help separate oil, gas, and water through mechanical and chemical processes. Central tank batteries (CTBs) centralize the separation and storage of oil, gas, and water from multiple wells in close proximity.
The main functions of a tank battery include:
Measurement in tank batteries involves testing and gauging the volume and quality of oil before it is sold. Safety components in tank batteries may include firewalls and pressure-relief valves. Tank batteries are crucial for efficiency, safety, and compliance with environmental regulations.
The overall tank batteries oil and gas design determines how efficiently your operation handles produced fluids from the moment the tank batteries oil and gas receive fluid from your wells until crude oil leaves for market. Professional construction directly impacts your bottom line and operational safety. The design and equipment selection for a tank battery depends largely on the specific characteristics of the produced fluids and operational requirements.
We construct complete new tank batteries oil and gas facilities for oil and gas operations starting from bare land.
Our greenfield development includes:
Full site preparation with proper grading, drainage, and foundation work.
Custom engineering based on expected production volumes and fluid characteristics.
Complete installation of processing tanks, separators, and storage and processing tanks.
Integration of control systems and safety equipment.
Permitting coordination with environmental and regulatory agencies.
A full tank battery is essential for handling the very first oil produced and for efficient storage and processing as soon as a well begins flowing. The produced fluid’s first stop is typically a separator, which is crucial for dividing the mixture into oil, gas, and water streams. You’ll also need a separator, both a regular and a test one, to separate gas from oil and water. Properly constructed tank bases distribute the weight of the tank and its contents, preventing soil settlement. Most tank batteries will require some sort of dike or firewall for safety and environmental protection.
Whether your wells produce under sufficient natural pressure or require pumping operations and gas lift systems, we design production facilities that match your specific requirements.
When production increases or new wells come online, existing systems often need expansion.
Our brownfield services include:
Adding storage tanks and processing equipment to accommodate higher fluid volumes.
Retrofitting existing oilfield tank batteries oil and gas systems with vapor recovery systems to meet current emissions regulations.
Upgrading separators and heater-treaters for improved separation efficiency.
Installing new flow lines and headers to connect additional wells.
Modernizing control and instrumentation systems.
Two Stock Tanks: A basic configuration often includes two stock tanks, which are atmospheric storage vessels used for temporarily holding oil prior to processing or sale. These tanks simply store fluid and allow for easy access to measure fluid levels.
Stock Tank: The stock tank is a non-pressurized vessel designed to store produced oil and water before further treatment or sale. Stored fluid in these tanks is held temporarily, and accurate measurement is essential for operational and regulatory purposes.
Wash Tank (Gun Barrel): A wash tank, also known as a gun barrel, is a vessel that separates oil from water and gas as part of the fluid processing and separation system within the tank battery.
Rectangular Tanks: Some facilities use rectangular tanks, which typically do not have a roof, making it easier to measure and test the contents. These tanks are usually not pressurized and may require modifications or additional equipment for safe operation.
API 12F Storage Tanks: High-capacity crude oil storage designed for storing oil prior to sale or transport. Unlike stock tanks used for temporary holding, these tanks meet API specifications for long-term reliability.
Three Phase Separators: These essential vessels separate oil, natural gas, and produced water from incoming well fluids. Proper sizing ensures adequate retention time to separate gas and separate oil effectively.
Two Phase Separators: Used where water content is minimal or where a simpler separation process is sufficient for the particular operation.
Heater-Treaters: Advanced treatment units that use heat and retention time to break emulsions and remove basic sediment and water (BS&W) from crude oil to meet sales specifications. Some heater-treaters and tanks operate at atmospheric pressure, which affects their design and safety features.
Produced Water Tanks: Specialized storage for separated water awaiting disposal or treatment. Most tank batteries oil and gas systems include dedicated water storage with proper containment.
Gas Processing Equipment: Vapor recovery units capture valuable gases that would otherwise be lost or flared. These systems can pay for themselves while reducing emissions.
Control Systems: Automated monitoring including level sensors, pressure relief, and emergency shutdown capabilities. Modern systems allow remote monitoring and control.
Safety Equipment: Fire suppression systems, H₂S detection, overfill protection, firewalls, pressure-relief valves, and emergency response equipment protect personnel and assets.
Flow Lines and Headers: Complete piping systems using large bore pipe or upset steel pipe, connecting wells to processing equipment. Proper sizing prevents bottlenecks even when head lines flow at peak capacity. All valves and lines in a tank battery should be clearly labeled for efficient operation.
Electrical and Instrumentation: Power distribution, hazardous area wiring, and monitoring systems including gauge line paste applications and tank chart systems for accurate level measurement. Using a gauge line paste helps determine the ratio of oil to water in tank batteries.
We evaluate your production requirements, soil conditions, and environmental factors before design begins. This includes analyzing:
Our engineering team develops a custom design based on your specific well characteristics and production forecasts. The tank battery receives fluid from your wells, and the design must account for the number and type of wells connected. Flow lines directing fluid into the tank battery can be constructed from upset steel pipe or synthetic materials like plastic or fiberglass, depending on site requirements. The first flow from a well is often measured by the drilling company, but ongoing measurement and record-keeping become the operator’s responsibility. Whether you’re handling fluid from a few different wells or building a central tank batteries oil and gas system serving an entire field, we size every component for optimal performance.
Tank batteries oil and gas construction requires coordination with multiple agencies. We handle:
Environmental permits including SPCC plan development.
Air quality permits addressing VOC and methane emissions.
State oil and gas commission approvals.
Local building and construction permits.
Coordination with safety agencies for H₂S handling and emergency response planning.
Our experience with regulatory requirements helps avoid delays and ensures your facility meets all applicable standards from day one.
Professional construction using certified welders and experienced crews ensures quality at every stage:
Foundation and civil work including ringwalls, containment berms, and drainage systems.
Tank erection following API 650 or API 12F specifications.
Separator and heater-treater installation with proper supports and connections.
Piping installation including steel lines for flow lines and process connections.
Welding performed by ASME-certified personnel with full NDE inspection.
Coating application for corrosion protection.
Quality control inspections occur throughout construction to verify compliance with design specifications and industry standards.
Before handover, every system undergoes comprehensive verification:
Pressure testing of vessels and piping.
Leak testing of all connections.
Functional testing of control systems and safety equipment.
Performance verification of separators and treatment equipment.
Calibration of measurement instruments and LACT units.
We provide operator training on all equipment and deliver complete documentation including as-built drawings, equipment manuals, and maintenance schedules.
Featured Case Study
PLC Construction was awarded the mechanical and instrumentation/electrical (I/E) construction of a centralized tank battery in the Permian Basin. Our scope included setting critical equipment, fabricating and installing pipe spools, hydrotesting all required piping, and performing complete installation and commissioning of electrical and safety systems.
Mechanical construction deliverables were completed in alignment with engineering specifications, incorporating a modular and standardized design approach. This strategy not only streamlined the current project but also established a scalable framework for future CTB developments—enabling faster design cycles, efficient construction, and improved adaptability across multiple sites.
By combining precision engineering with expert execution, PLC delivered a facility that operates efficiently and autonomously, reinforcing our commitment to excellence in oil and gas infrastructure projects.
From Design to Operation—We Make It Seamless
Our team is committed to delivering high-quality workmanship, exceptional customer service, and timely completion within budget. By combining precision engineering with expert execution, PLC ensures every facility operates safely, efficiently, and autonomously.
Partner with PLC Construction today –
Our dedicated team provides full EPC services for a plethora of industries and projects nationwide. When you partner with PLC, you gain more than a contractor—you gain a true EPC partner committed to technical excellence, operational efficiency, and long-term value.
Client:
Energy Company
Location:
Permian Basin, Texas
Industry:
Sustainable Energy Producer
Service:
Construction –Mechanical & I&E
A tank battery is an essential upstream oil and gas facility consisting of a group of interconnected tanks and equipment used to store, separate, and treat raw hydrocarbons. Tank batteries help separate oil, gas, and water through mechanical and chemical processes. Central tank batteries (CTBs) centralize the separation and storage of oil, gas, and water from multiple wells in close proximity. Measurement in tank batteries involves testing and gauging the volume and quality of oil before it is sold. Safety components in tank batteries may include firewalls and pressure-relief valves. Tank batteries are crucial for efficiency, safety, and compliance with environmental regulations.
Timeline varies based on size and complexity. A smaller test tank setup or single tank batteries oil and gas system might be completed in 4-8 weeks, while a full central tank batteries oil and gas system serving multiple wells typically requires 3-6 months. Factors affecting schedule include permitting timelines, equipment lead times, weather conditions, and site accessibility. We provide detailed project schedules during the engineering phase.
Most tank batteries oil and gas projects require:
State oil and gas commission approval
Environmental permits addressing spill prevention and air emissions
Local building permits
Potentially wetlands or stormwater permits depending on location
Sour crude facilities handling hydrogen sulfide may require additional safety reviews. We coordinate all permitting as part of our standard project delivery.
Yes. We offer maintenance packages that include regular inspections per API 653 requirements, equipment servicing, instrumentation calibration, and coating maintenance. Proper ongoing care ensures your tank batteries oil and gas system delivers reliable performance and meets regulatory requirements throughout its service life.
Tank batteries oil and gas system size depends largely on your production volumes, fluid characteristics, and growth plans. A single tank battery typically receives fluids from just one well, and its design is tailored specifically to that well’s production type and parameters. A single tank battery receives fluid at rates that can vary widely—some handle such a small flow that minimal equipment is needed, while high-volume operations require extensive separation and storage capacity. Initial production may have a satisfactory flow due to natural reservoir pressure, but this will naturally drop over time. The well’s production lift and very first production are important for determining equipment needs and planning for regulatory compliance. When natural pressure declines, a gas lift system can be installed to maintain production. We analyze your well test data, drill stem test results, and production forecasts to recommend appropriately sized equipment.
Absolutely. Many clients have stock tanks, wash tanks, or other equipment that can be incorporated into new tank batteries oil and gas construction. Some tanks in the system simply store fluid, serving as temporary storage before further processing or sale. Tank batteries may also handle other produced fluids such as water and gas, not just oil, requiring proper separation and storage solutions. We evaluate existing assets and recommend which components can be reused versus replaced. Sometimes simple additions like a smaller test tank or circulation pump can significantly improve performance. Understanding how each basic component works is essential to adapt to changing production needs and ensure efficient operation.
