Weir Height Design in case of three phase horizontal separator

The height of the oil weir controls the liquid level in the vessel. The difference in height of the
oil and water weirs and specific gravity differences control the thickness of the oil pad. It is
critical to the operation of the vessel that the water weir height be sufficiently below the oil weir
height so that the oil padd thickness provides sufficient oil retention time. If the water weir is too
low or the difference in specific gravity is not as great as anticipated, then the oil pad could grow
in thickness to a point where oil will be swept under the oil box and out the water outlet.
Normally, either the oil or the water weir is made adjustable so that changes in oil/water specific
gravities or flow rates can be accommodated.

To obtain a desired oil pad height, the water weir should be set a distance below the oil weir,
which is calculated by the following equation developed by equating the sta
static
tic heads at point A

in Figure 1

Figure 1: Schematic used for calculating the required height difference between the oil and
water weirs in a bucket
bucket-and-weir type of horizontal three phase separator

Where,
∆hh = height difference between the oil and water weir, in
ho = desired oil pad height, in
ρo = oil density, lb/ft3
ρw = water density, lb/ft3

In general, a bucket and weir design is most effective for applications with high water-to-oil
water
flow rates and/or small density differences. Interface control should be considered for
applications with high oil flow rates and/or large density differences. In applications where large
amounts of emulsion or paraffin are anticipated, it may be difficult to sense interface level. In
such a case, bucket and weir control is recommended.

Liquid flowing over a weir behaves as shown in Figure 2

Figure 2: Flow of liquid over the weir

The height of liquid above the weir depends on the flow rate. For separator flow rates, the height
of liquid above the weir, F, is generally small, on the order of inches, and is often neglected in
solving Equation 1. However, where large surges of water production are possible, it may be
necessary to check that the actual
al height of water above the weir as it may cause water to flow
over the oil weir. Secondly, where large surges of oil are possible, it may be necessary to check
that the actual height of oil above the oil weir as it may cause oil to flow beneath the oil bucket
buc
and out with the water.

The Francis weir formula provides a reasonable first approximation for height of liquid above a
weir:

𝑄 = 3.33 𝐵 (𝐹)

Where
Q = Flow rate, ft3/s
B= Width of weir, ft
F= height of liquid over weir, ft

A more complete equation which considers the effects of "drawdown" of the fluid is:

𝑄 = 5.35 𝐵𝐶(𝐹)
Where
Q = Flow rate, ft3/s
B= Width of weir, ft
F= height of liquid over weir, ft
C= Coefficient of discharge

The coefficient C was found by Rehbock to obey the following empirical formula:

ft
Steps for the determination of weir height:

1. Solve F1 using following equation

equation:

2. Calculate the coefficient of discharge:

3. Solve for new F value:

4. Repeat step 2 using the new F for F1, then solve Equation (6) using the new C.

5. To get the actual liquid height in the separator, F must be added to the weir height, or to get
the weir height for a given liquid height, F must be subtracted from the liquid height.