Liquid Carry Over

Sure it's possible, how are you measuring the volume in the tank. How big is the tank? Is the tank inlet and outlet valves closed (isolated) when you are measuring the tank height.

I don't understand, are you flowing gas or flowing crude oil.

By gas I assuming you mean natural gas not NGL's eg: butane propane etc.

If you are flowing natural gas it will remain as a gas at very high pressures(>3000 psi). Butane and propane however will becaoma liquid at <100 psi.

The key feature is to look at what gas volume (please ensure you use ACTUAL m3/hr) for which the vessel was designed. Separator vessels use gravity to separate liquids and gases. For this to work gravity has to exceed the upward drag of the gas. This is done by dropping the velocity of the gas and alowing suffcient residence time in the vessel for the liquid to drop out. (The key calcs for this can all be found in GPSA)

If you are operating at a lower pressure than originally then the gas velocities will increase and residence time will fall making the separation worse (although the density difference will widen so improving the spearation). Also if the liquids are of a lower density than originally they will be less easy to separate.

Most separators also have outlet devices (from simple mist mats to deflectors etc) if these are now missing have holes are are otherwise deficient this will reduce the effectiveness of the gas / liquid separation.

Overall what I am trying to say is that you may be getting liquid carryover because for any one of a number of reasons not all of the liquid was separated from the gas. Consequently you need to look at the original design basis, your current flows and sizing calcs

Inefficient gas-liquid separation, re-entrainment, flooding, etc...will lead to liquid carry over during normal operation even though the HIGH liquid level is not reach

I didn't see the word seperator anywhere in his initial text. It might be useful to include a schematic in your discussion or a digital picture of the setup with some commentary.

I see the that crude and natural gas is being produced into the same system. (eg. solution gas and crude oil or some wells producing high levels of natural gas)

Position of the HP vessel you are speaking of (knock out drum, seperator, HP tank) would be helpful.

If you are speaking of a seperator I agree with the gentlemans recommendations and conclusion.

Go back to the design criteria , maybe something has changed on the conditions.