The gas-liquid cylindrical cyclone (GLCC©, The University of Tulsa, 1994) is a simple, compact, and low-cost separator, which provides an economically attractive alternative to conventional gravity-based separators over a wide range of applications. The GLCC© inlet section design is a key parameter, which is crucial for its performance and proper operation. An in-depth evaluation of specific design modifications and their effect on safety and structural robustness are carried out in this study using finite element analysis (FEA). Fluid–structure interaction (FSI) analysis is also carried out using the results of computational fluid dynamics (CFD) aimed at investigating the effect of fluid flow on the inlet section structural integrity. The selected design modifications are based on feasibility of GLCC© manufacturing and assembly for field applications. Different case studies incorporating sustained GLCC© internal pressure, dead weight loading, forces generated because of slug flow and high temperatures are analyzed and presented in this paper. The concept of holes cut out in baffle has been effective with no stresses or deformation in the baffle area. FSI simulation of slug flow has proved that FEA direct loading case studies are far more conservative.