Study of Gas Separator Performance and Liquid Carryover in Gas Processing Operations in Akwa Ibom State

Gas-liquid separators are fundamental process vessels in natural gas production and processing, and their performance directly affects gas quality and the protection of downstream compression and processing equipment. This study evaluates the performance of gas-liquid separators at an upstream gas processing facility in Akwa Ibom State, focusing on two-phase and three-phase separators operating at wellhead gathering and gas inlet separation stages. The research employs a process engineering assessment methodology, combining operational data analysis, liquid carryover measurement using isokinetic sampling, and ASME VIII pressure vessel inspection records. Key performance indicators assessed include liquid carry-over rates, gas carry-under in liquid outlets, separator inlet momentum values, demister pad condition, and the adequacy of interface level control systems. The study investigates the root causes of periodic liquid carryover events, including separator overloading during production rate surges, degraded demister mist extractor elements, and inadequate liquid dump valve response times. Findings demonstrate that liquid carryover exceeds the design limit of 0.1 gallons per million standard cubic feet on at least four occasions per month on average, contributing to compressor suction liquid knock events and associated compressor maintenance costs. Recommendations include installation of slug catchers upstream of the separators, demister pad replacement on a 3-year schedule, and adoption of real-time separator liquid level alarms. Keywords: gas separator, liquid carryover, gas processing, Akwa Ibom, process performance.