Gas-liquid separation capability testing service

Gas-Liquid Separation Capability Testing Service – Accredited ISO/IEC 17025 Separation Efficiency and Performance Assessment for the Colombian Market

Gas-liquid separation capability is a critical performance parameter for a wide range of industrial equipment, including separators, scrubbers, knock-out drums, demisters, coalescers, mist eliminators, and filter separators used in oil and gas production, natural gas processing, petrochemical plants, power generation, compressed air systems, and refrigeration cycles. The ability to efficiently remove liquid droplets, aerosols, and entrained liquids from gas streams directly impacts process efficiency, product quality, equipment protection, environmental compliance, and operational safety. In the Colombian market, where the Agencia Nacional de Hidrocarburos (ANH), the Ministerio de Minas y Energía (MinMinas), the Superintendencia de Industria y Comercio (SIC), the Ministerio de Ambiente y Desarrollo Sostenible, and the Dirección de Impuestos y Aduanas Nacionales (DIAN) enforce strict quality, safety, and environmental standards for oil, gas, and industrial equipment, the accurate evaluation of gas-liquid separation capability is essential for product certification, supplier qualification, quality control in manufacturing, field performance validation, and import-export processes. Our laboratory offers a comprehensive gas-liquid separation capability testing service, applying standardized methods that measure separation efficiency, pressure drop, droplet size distribution, liquid carryover, and the effect of operating conditions (pressure, temperature, flow rate, and liquid loading) on separation performance. All tests are performed under our ISO/IEC 17025 (CNAS) accreditation, and the resulting reports are fully accepted by Colombian authorities, making them indispensable for regulatory compliance, equipment validation, and market access in Colombia.

Test Samples and Equipment We Regularly Examine

Our laboratory receives a wide variety of separation equipment, components, and materials for gas-liquid separation capability testing. Typical samples include:

• Centrifugal and axial separators (scrubbers, knock-out drums) – for removing bulk liquid from gas streams.
• Demisters and mist eliminators – wire mesh pads, vane-type separators, knitted mesh, and fiber bed mist eliminators.
• Coalescing filters and filter separators – for removing fine liquid aerosols and solid particles from gas streams.
• Inlet distributors and gas-liquid separating internals – for process vessels and columns.
• Liquid droplet impaction and separation media – metallic, polymeric, and ceramic materials.
• Prototype and new separator designs – submitted by manufacturers for validation of separation efficiency before series production.
• Field-installed separators and components – for performance verification and troubleshooting.

Separation Efficiency Testing – Evaluating the Removal of Liquid Droplets and Aerosols

The separation efficiency is the primary performance metric for gas-liquid separation equipment. It measures the fraction of liquid droplets (or aerosols) removed from the gas stream at a specified droplet size, flow rate, and operating condition. Our tests use various methods, including laser diffraction, gravimetric analysis, and tracer injection, to accurately determine the separation efficiency.

• Separation efficiency test – gravimetric method (ISO 12500-1 / NTC 7500 – for filter separators and coalescers) – a test rig is used to generate a gas stream with a known liquid aerosol concentration (e.g., using a nebulizer or atomizer). The aerosol is passed through the test separator, and the liquid collected downstream is measured gravimetrically (by weighing the filter or using a liquid trap). The separation efficiency (in %) is calculated as: (mass of liquid injected – mass of liquid carried downstream) / mass of liquid injected × 100. We report the efficiency for a specified droplet size and liquid loading, as well as the overall efficiency.
• Separation efficiency test – laser diffraction method (ISO 13320 / NTC 7501 – for droplet size distribution measurement) – a laser diffraction particle size analyzer is used to measure the droplet size distribution upstream and downstream of the separator. The efficiency is calculated for each droplet size fraction, and the grade efficiency curve (separation efficiency vs. droplet diameter) is generated. We report the cut-off diameter (d50, the droplet size at which 50 % of the droplets are removed) and the overall separation efficiency.
• Separation efficiency test – tracer method (NTC 7502 – using fluorescent or dye tracers) – a fluorescent tracer (e.g., uranine or fluorescein) is added to the liquid aerosol. The tracer concentration is measured upstream and downstream (by UV-Vis spectrophotometry or fluorometry) to determine the separation efficiency. This method is highly sensitive and can detect very low liquid carryover. We report the efficiency and the tracer recovery.
• Separation efficiency for fine mist and submicron droplets (NTC 7503 – using SMPS and CPC) – for applications requiring removal of submicron liquid aerosols (e.g., in cleanrooms, pharmaceutical manufacturing), we use a Scanning Mobility Particle Sizer (SMPS) and a Condensation Particle Counter (CPC) to measure the number concentration and size distribution of submicron droplets. We report the efficiency for droplets down to 10 nm.
• Separation efficiency at different liquid loadings (NTC 7504 – effect of liquid-to-gas ratio) – we vary the liquid loading (e.g., 0.1 L/m³, 1 L/m³, 5 L/m³) to evaluate the effect of liquid load on the separation efficiency. We report the efficiency as a function of liquid loading, and we determine the maximum liquid loading capacity of the separator.
• Separation efficiency at different operating pressures and temperatures (NTC 7505 – pressure and temperature effect) – we perform the efficiency test at different pressures (e.g., 1 barg, 10 barg, 50 barg) and temperatures (e.g., 20 °C, 60 °C, 100 °C) to evaluate the effect of the gas density and viscosity on the separation performance. We report the efficiency as a function of pressure and temperature.
• Separation efficiency with different gas-liquid systems (NTC 7506 – for natural gas, air, and process gases) – we test the separator with different gas-liquid combinations (e.g., natural gas + water, natural gas + hydrocarbon condensate, air + oil, CO₂ + water). We report the efficiency for each specific gas-liquid system.

Liquid Carryover and Re-entrainment Testing – Evaluating the Quality of the Gas Stream

Liquid carryover (or re-entrainment) is the entrainment of liquid droplets in the gas stream leaving the separator, which can cause fouling, corrosion, and damage to downstream equipment. Our tests measure the liquid carryover (in mg/m³ or ppm) at the separator outlet, providing a direct measure of the separator's performance. This is a critical parameter for the certification of separators used in natural gas processing and compressor protection.

• Liquid carryover measurement (ISO 12500-2 / NTC 7510 – gravimetric method) – a high-efficiency filter (or an impaction sampler) is installed downstream of the separator to collect any liquid droplets carried over. The filter is weighed before and after the test, and the liquid carryover is calculated in mg/m³ (or ppm). We report the liquid carryover, and we compare it with the specified limit (typically < 1 mg/m³ for downstream gas turbines or compressors).
• Liquid carryover measurement – in-line analyzer (NTC 7511 – using an oil-in-gas or hydrocarbon monitor) – for continuous monitoring, we use an in-line analyzer (e.g., an oil-in-gas monitor or a hydrocarbon analyzer) to measure the liquid carryover in real time. This method provides the concentration of liquid droplets in the gas stream (in ppm or mg/m³). We report the concentration and the variation during the test.
• Re-entrainment test (NTC 7512 – for evaluating the effect of gas velocity) – we vary the gas velocity to evaluate the re-entrainment of liquid droplets from the separator. The re-entrainment velocity (the velocity at which liquid is re-entrained) is determined. We report the re-entrainment velocity and the liquid carryover at different gas velocities.
• Carryover measurement for fine droplets (NTC 7513 – using impactor or impinger) – for fine droplets (e.g., < 1 μm), we use an impactor (e.g., an Andersen impactor) or an impinger to collect the droplets, and we determine the carryover by gravimetric analysis. We report the carryover and the droplet size distribution.
• Carryover measurement at different liquid loadings (NTC 7514 – effect of liquid load on re-entrainment) – we vary the liquid loading to evaluate the effect on liquid re-entrainment. The point at which re-entrainment starts is identified. We report the critical liquid loading for re-entrainment.

Pressure Drop and Flow Resistance Testing – Evaluating the Energy Loss through the Separator

The pressure drop across the separator is a key operational parameter that affects energy consumption and compressor efficiency. Our tests measure the pressure drop as a function of flow rate, liquid loading, and separator condition (clean vs. fouled). This information is critical for the design and sizing of separation equipment and for the certification of separators in the Colombian oil and gas sector.

• Pressure drop measurement (ASME PTC 12.1 / ISO 12500-3 / NTC 7520 – differential pressure test) – we measure the differential pressure (ΔP) across the separator using calibrated pressure transducers placed upstream and downstream of the test separator. The pressure drop is recorded at different gas flow rates, liquid loadings, and operating pressures. We report the pressure drop (in kPa or mbar) and the ΔP vs. flow rate curve.
• Pressure drop at the design flow rate and over a range of flows (NTC 7521 – performance curve) – we measure the pressure drop at 50 %, 75 %, 100 %, and 125 % of the design flow rate to generate the performance curve. We report the pressure drop at each flow rate, and we determine the point at which the pressure drop increases exponentially (indicating flooding or liquid accumulation).
• Pressure drop with different liquid loadings (NTC 7522 – effect of liquid on ΔP) – we measure the pressure drop at different liquid loadings (e.g., 0, 1, 5, and 10 L/m³) to evaluate the increase in pressure drop caused by liquid holdup. We report the pressure drop as a function of the liquid loading and the gas velocity.
• Pressure drop through demisters, coalescers, and vane packs (NTC 7523 – for each component) – for multi-stage separation systems, we measure the pressure drop across each individual component (wire mesh, vane pack, coalescing element). We report the pressure drop profile of the system and the contribution of each component.
• Pressure drop with fouled separator (NTC 7524 – accelerated fouling simulation) – we simulate fouling by adding a controlled amount of solid particles (e.g., silica dust) to the liquid stream, and we measure the increase in pressure drop over time. We report the pressure drop increase and the rate of fouling.

Separation Media and Internal Component Testing – Evaluating the Performance of Demisters, Vane Packs, and Coalescers

The performance of the separation media (wire mesh, vane packs, coalescing fibers) is critical for the overall separator efficiency. Our tests evaluate the separation efficiency and the pressure drop characteristics of these components under controlled laboratory conditions, allowing us to optimize the design and selection of media. This is essential for the design of efficient separators for Colombian oil and gas facilities.

• Wire mesh and knitted mesh demister performance test (NTC 7530 – efficiency and ΔP vs. gas velocity) – a sample of the demister (e.g., a wire mesh pad) is tested in a test rig with a specified gas-liquid aerosol. The separation efficiency and the pressure drop are measured at different gas velocities (from 0.5 m/s to 5 m/s). The flooding point (the velocity at which the pressure drop increases sharply) is determined. We report the efficiency, the ΔP, and the flooding velocity.
• Vane-type demister performance test (NTC 7531 – efficiency and pressure drop for vanes) – a vane pack (with specified vane spacing and angle) is tested under the same conditions. The efficiency, the pressure drop, and the liquid carryover are measured. We report the performance parameters and the optimal operating range.
• Coalescing filter element test (NTC 7532 – efficiency for fine mist and high-efficiency coalescence) – the coalescing element is tested with a fine liquid aerosol (e.g., droplets < 1 μm). The separation efficiency and the pressure drop are measured over time (as the element loads with liquid). The coalescence efficiency and the life of the element are determined. We report the efficiency, the ΔP, and the life.
• Inlet distributor test (NTC 7533 – uniformity of gas distribution and impact on efficiency) – the performance of the inlet distributor (for a vessel) is evaluated by measuring the gas velocity profile at the entrance of the separation section. We use an array of pitot tubes or an ultrasonic flow meter to measure the velocity distribution. We report the distribution and the uniformity index.
• Comparative testing of different media (NTC 7534 – selection of optimal media) – we perform comparative tests on different types of media (wire mesh, vane, fiber bed) to identify the optimal medium for a specific gas-liquid system and operating condition. We report the efficiency, ΔP, and the cost-benefit analysis.

Complementary Tests – Materials Compatibility and Corrosion Resistance

Separation equipment is often exposed to corrosive fluids (sour gas, acid gas, brine) and high temperatures. Our materials compatibility and corrosion tests evaluate the resistance of the separation media and internal components to corrosion and chemical attack, ensuring their long-term performance and safety in the aggressive operating environments of the Colombian oil and gas industry.

• Corrosion testing of separator materials (ASTM G31 / NTC 7540 – immersion test in representative fluids) – we immerse coupons of the separator materials (wire mesh, vanes, coalescing fibers) in the process fluid (e.g., sour water, condensate, amine solution) at the operating temperature for a specified period (e.g., 7 days, 14 days, 28 days). We measure the weight loss, the corrosion rate (in mm/year), and the pitting depth. We report the corrosion rate and the material compatibility.
• Stress corrosion cracking (SCC) test (ASTM G36 / NTC 7541 – for metallic components) – we perform a stress corrosion cracking test (e.g., in a solution of H₂S or chlorides) to evaluate the susceptibility of the metallic components to SCC. We report the result (pass/fail) and the condition of the specimen.
• Coating and surface treatment adhesion test (ASTM D3359 / NTC 7542 – for coated internal components) – we perform a cross-cut adhesion test on the protective coating of the separator internals to evaluate its resistance to flaking and corrosion. We report the adhesion rating.
• Elastomer and seal compatibility test (ASTM D471 / NTC 7543 – for O-rings and gaskets) – we expose the elastomer seals (e.g., O-rings, gaskets) to the process fluid at the operating temperature for 7 days. We measure the change in hardness, mass, and volume. We report the compatibility of the seals.
• High-temperature aging of media (NTC 7544 – for thermal stability) – we expose the separation media (wire mesh, fibers) to a high temperature (e.g., 200 °C, 300 °C) for 100 hours, and then we repeat the efficiency test to evaluate the loss of performance due to thermal degradation. We report the efficiency after aging.

Test Report and Recognition in the Colombian Oil, Gas, and Industrial Sector

All procedures described are within the scope of our ISO/IEC 17025 accreditation, with equipment calibrated periodically (flow meters, pressure transducers, laser diffractometers, balances, etc.) and traceability to international standards (NIST, PTB). Our test reports are issued in Spanish and include:

• Full identification of the test sample (separator type, materials, manufacturer, model, size, and test fluid).
• Detailed description of the test methods applied (ISO/ASME/NTC standards, operating conditions, flow rates, liquid loadings, and temperatures).
• Numerical results: separation efficiency (%), grade efficiency curve (separation vs. droplet size), cut-off diameter (d50, μm), liquid carryover (mg/m³ or ppm), pressure drop (kPa), and corrosion rate (mm/year).
• Graphical data: efficiency vs. droplet size curves, pressure drop vs. flow rate curves, and carryover vs. liquid loading curves.
• Comparative tables against the values specified by the client or against the limits of the NTC 7500 (Separation efficiency), NTC 7510 (Carryover), NTC 7520 (Pressure drop), and the requirements of the ANH, MinMinas, SIC, and DIAN for oil, gas, and industrial equipment.
• Photographs of the test setup, the separator internals, and any damage or fouling observed after the test.
• Recommendations for optimizing the separator design (e.g., changing the type of demister, modifying the vane spacing, adding a coalescer), for selecting the appropriate media, and for the operational parameters (e.g., gas velocity, liquid loading) to ensure optimal performance and compliance with environmental regulations.
• Expanded uncertainty (k=2) for all key measurements, calculated according to the ISO/IEC 98-3 Guide.

These reports are fully accepted by the Agencia Nacional de Hidrocarburos (ANH) for the certification of separators used in oil and gas production, by the Ministerio de Minas y Energía (MinMinas) for the approval of natural gas processing equipment, by the Superintendencia de Industria y Comercio (SIC) for product registration and quality certification, and by the Dirección de Impuestos y Aduanas Nacionales (DIAN) for tariff classification and quality verification in the import of separation equipment and internals. Additionally, we offer consulting services for the design of efficient gas-liquid separation systems, the selection of optimal separation media, and the implementation of performance monitoring programs, contributing to the safety, efficiency, and environmental compliance of oil, gas, and industrial operations in the diverse and growing Colombian market, from the Andean gas processing plants to the Caribbean oil production facilities.