Top Engineering Challenges in Designing Vapor Recovery & Emissions Control Systems—and How to Solve Them

Designing effective emissions control systems in oil and gas production isn’t just about checking a regulatory box. When engineered well, vapor recovery solutions can increase production efficiency, reduce tank pressure issues, prevent product loss, and turn what would have been emissions into measurable revenue.

But in real-world field environments—especially in high-volume basins like the Permian—designing a vapor recovery system that performs consistently isn’t simple. Tank batteries don’t behave like controlled simulations, production changes over time, and gas composition isn’t always predictable. The difference between a system that pays for itself in 12 months and one that continually fails often comes down to engineering.

Based on common field conditions, here are the top engineering challenges operators face and how smart system design solves them.

1. Incorrect VRU Sizing for Real Tank Behavior

Many systems are sized based on theoretical or early-flow estimates—but actual tank vapor behavior changes dramatically based on:

• Temperature

• Flash gas load

• Separator pressure

• Truck loading cycles

• API gravity and volatility

If a VRU is undersized, operators see tank pressure spikes, venting events, or safety flare activation. If it’s oversized, compressors short-cycle, causing premature wear and costly downtime.

How to solve it:

• Use real production and flash gas data—not generic sizing tables

• Model high- and low-volume operating conditions

• Design for turndown flexibility, not peak flow only

This is a core design principle behind Altara’s VRU & gas lift compression solutions, which are engineered to maintain consistent performance even as production declines.

2. Liquid Carryover Damaging Compressors

Tank vapors carry entrained liquids, corrosion particles, paraffin solids, and condensate droplets. If the system doesn’t properly condition inlet gas, these liquids reach the compressor and cause:

• Valve damage

• Seal failure

• Excessive cylinder wear

• Shutdown events

How to solve it:

• Install effective knockout systems ahead of the VRU skid

• Include automatic drain systems

• Use corrosion-resistant materials where needed

• Add filtration based on gas composition

Proper inlet separation protects asset life and reduces unplanned maintenance.

3. Tank Pressure Control & Safety Failures

Tank batteries are dynamic—not static storage vessels. Incorrect pressure balancing leads to:

• Over-pressurization and tank venting

• Vacuum conditions (which can collapse tanks)

• Spillover into flare systems

• Increased emissions and safety risks

How to solve it:

• Balance vapor lines across tanks instead of isolated pulls

• Set intelligent pressure setpoints in the controller logic

• Use properly sized pressure-vacuum relief valves

• Design for truck loading and agitation conditions

Good pressure control reduces both emissions and emergency releases.

4. Gas Composition Variability & Material Compatibility

Gas composition in the field isn’t uniform. H₂S, CO₂, nitrogen, and varying BTU levels all affect:

• Compressor metallurgy

• Seal materials

• Lubricant selection

• Control systems

• Corrosion protection

A system designed for lean gas may fail rapidly in sour or high-BTU environments.

How to solve it:

• Test gas composition when sizing the system

• Select materials based on exposure

• Include gas analysis in maintenance schedules

Designing with real chemistry in mind reduces failures and downtime.

5. Control Logic & Automation Issues

Even perfectly sized mechanical equipment fails without the right control strategy. Poor PLC configuration can lead to:

• Short-cycling

• False shutdowns

• Over-pulling tanks into vacuum

• Startup failures

• Lack of communication with SCADA

How to solve it:

• Use field-tested PLC logic instead of generic control panels

• Integrate alarms, slow-ramp startups, and tank pressure feedback

• Include telemetry for remote diagnostics

Systems run longer and require fewer callouts when control logic matches field conditions.

6. Lack of Ongoing Service & Operational Support

A VRU isn’t set-and-forget equipment. Without routine checks, operators see:

• Scaling and fouling

• Loss of efficiency over time

• Compressor wear

• Increased emissions events

How to solve it:

• Implement preventative maintenance schedules

• Monitor compression performance and vapor loads

• Keep parts on hand for common wear points

Operators often see the highest ROI when pairing equipment installs with field service and emissions support, not just a one-time skid delivery.

How Altara Designs Solutions That Solve These Challenges

Altara approaches emissions control with real-field engineering, not one-size-fits-all equipment. Their solutions focus on:

• VRU & gas lift compression solutions

• Stabilization systems

• Vapor recovery design consulting

• Service + preventative maintenance programs

Systems are engineered for:

• Tank pressure stability

• Liquid handling and separation

• Real-world gas composition

• Long-term asset performance

• Revenue-focused emissions reduction

Whether upgrading existing batteries or designing new infrastructure, the goal is consistent performance, not just compliance.

Ready to Improve Your Vapor Recovery Performance?

If you’re evaluating emissions control systems or planning upgrades to improve reliability and product capture: