This article aims to enhance the reliability, efficiency, and diagnostic capabilities of gas-liquid separators operating in hazardous technological processes. In the study, the separator is considered as a critical functional unit of an industrial system and is analyzed through structural and functional decomposition. The main operating parameters of the separator, including pressure drop (ΔP), separation efficiency and operational state are described on the basis of a mathematical model. In addition, a state model is developed for normal operation, foaming, liquid droplet carryover with the gas flow, and failure conditions. Emphasis is placed on diagnostic and monitoring issues, and the possibilities of implementing condition assessment and early warning algorithms based on the Plant Resource Manager (PRM) platform are examined. The proposed approach contributes to improving separator reliability, preventing emergency situations, and ensuring the overall safety of hazardous production processes.
Muxitdinov et al. (2026) studied this question.