REDUCTION OF THE AMOUNT OF CONDENSATE ENTERING THE COMPRESSOR BY IMPLEMENTING DESIGN MODIFICATIONS IN THE GAS COMPRESSOR SEPARATOR

Reliable and long-term operation of gas compressors largely depends on the effective prevention of liquid phase ingress, particularly condensate, into the compressor flow path. Liquid carryover with the gas stream accelerates erosion processes, causes mechanical damage to internal compressor components, increases vibration levels, contaminates the lubrication system, and ultimately reduces the overall efficiency and reliability of the equipment. These issues are especially critical for high-speed and heavily loaded gas compressors operating under continuous service conditions. Separators installed at the inlet of gas compressors play a crucial role in the gas–liquid separation process. However, operational experience indicates that existing separator designs do not always provide the required separation efficiency under real operating conditions. High gas velocities, reduced condensate droplet sizes, non-uniform flow distribution, and insufficient performance of demister elements contribute to liquid carryover and subsequent condensate ingress into the compressor. This study investigates methods for reducing the amount of condensate entering a gas compressor by implementing design modifications to the inlet separator. The operating principle and structural features of the existing separator are analyzed, and key operational deficiencies are identified. The main hydrodynamic and design parameters influencing gas–liquid separation efficiency are determined. Based on the analysis, technical solutions are proposed, including optimization of the separator internals, improvement of inlet flow distribution, enhancement of demister elements, and upgrading of the condensate collection and drainage system. The implementation of the proposed design modifications resulted in a significant reduction in condensate carryover at the compressor inlet, stabilization of operating parameters, and an overall improvement in equipment reliability. The results confirm that optimizing separator design is an effective approach to enhancing the safety, efficiency, and service life of gas compressors and can be recommended for application in similar process systems. Keywords: Gas compressor, separator, condensate, gas–liquid separation, design modification, demister, operational reliability.