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James P. Brill, who joined the U.

of Tulsa in 1966 asan assistant professor and is


now the F.M. Stevenson Professor of petroleum engineering, developed the U. of
Tulsa Fluid Flow Projects in 1973. He has worked at Chevron Ol Field Research
Co., Amoco Production Co., and as a two-phase-flow consultan!. Brill holds a BS
degree from the U. of Minnesota and a PhD degree in petroleum engineering from
the U. of Texas. He is a member of the Distinguished Lecturer Committee and was
a 1982 Distinguished Lecturer, a member of the 1978-81 Engineering Manpower
Commttee, 1971 and 1976 SPE Annual Fall Meeting Education and
Professionalsm Technical Program Commttee, and 1967-70 Educaton and
Accredtaton Commttee.

Multiphase Flow in Wells


James P. Brill, SPE, U. of Tulsa

Summary. Multiphase flow can occur throughout the production system. The fluids involved in multiphase
flow in the petroleum industry are multicomponent mixtures with complex phase behavior. Petroleum engineers
are faced with the need to predict the relationships between flow rates, pressure drop, and piping geometry for
reservoir fluids produced during the life of a field. This paper reviews the historical development of design
tools used to address these unique multiphase-flow features. State-of-the-art technology is also presented.
lntroduction
Multiphase flow can occur throughout the entire Temperatures can range from 400F [200C] to
production system involved in flowing fluids from oil below the freezing temperature of water. Pipe lengths
and gas reservoirs to processing facilities at the can vary from a few fect to severa! hundred miles for
surface. The production system in this context surface pipe or pipelines and from a few hundred feet
includes the reservoir: the well completion; the to more than 20,000 ft [6100 mj for wells. Piping
tubulars that connect the reservoir to the surface; ali systems often involve significant variations in
surface facilities on land, seabed, or offshore geometry, such as inclination angle, diameter, pipe
platform; and any pipelines that carry produced fluids roughness, and even shape, such as when fluids flow
to other processing facilities. The multiphase flow in the annular space between casing and tubing in a
encountered in producing oil and gas can be any wellbore. Although most vertical piping systems
combination of a natural gas phase, a hydrocarbon involve upflow, it is not uncommon to have
liquid phase, and a water phase. multiphase downward flow in injection wells or
A vast amount of technical information on downcomers connecting offshore platforms to subsea
multiphase flow in pipes is available in the literature. pipelines. Simulating multiphase flow in wells also
Many of these sources are related to other industries requires the ability to predict fluid temperatures in a
and involve different types of fluids. The reference system that undergoes complex heat transfer
list for this paper clearly demonstrates the diversity of phenomena between the reservoir and the surface.
interest in multiphase flow in pipes. In particular, The entire wellbore is surrounded by a huge rock
significant contributions have been made in the volume, much of which may even be frozen, as in
nuclear industry, where a major concern is a possible the case of permafrost in arctic locations.
loss-of-coolant accident in a nuclear reactor. These Engineers in the petroleum industry are faced with
studies involve the transient simulation of two-phase, the requirement to predict the relationships between
single-component (water) fluid flow in piping flow rates, pressure drop, and piping geometry
systems. (length, diarneter, angle, etc.) for the fluids produced
Multiphase flow in the petroleum industry has many from a reservoir over the entire life of the field. The
unique features that create complications not objective of this paper is to review the historical
encountered by other industries. The fluids involved development of design tools used to address the
are multicomponent mixtures whose phase behavior is unique multiphase-flow features of the petroleum
extremely complex. The range of pressures and industry, including an evaluation of the state of
temperatures encountered in production systems is the art.
extremely broad. Pressures can range from 15,000
psia [100 MPa] to near atmospheric conditions. Historical Development
The development of tools to assist engineers in
Copyright 1987 Society of Petroleum Engineers predicting multiphase-flow behavior in wells, and thus

Journal of Petroleum Technology, January 1987 15


Any errors in the equation were automatically
t t t t incorporated into a single empirical mixture friction
factor, which was correlated with measured data. The
most commonly used early correlations of this type
were developed by Poettmann and Carpenter, 1
Baxendell and Thomas, 2 and Fancher and Brown. 3
Ali three studies neglected the last term in Eq. 1,
which represents kinetic energy effects.

Generalized Empirical Correlations. As the early


prolific fields declined in productivity and much
smaller fields were found and developed, it became
obvious that homogeneous models were no longer
sufficient to size tubing properly. At lower flow
rates, significant differences exist between the
velocities of the gas and liquid phases, a phenomenon
..... known as "slippage." In addition, the gas and liquid
no longer exist as homogeneous mixtures, but rather
form much different geometrical configurations. The
configurations or flow patterns found in vertical

t
BUBBLE SLUG
t t
CHURN
t ANNULAR
FLOW
upward flow are shown in Fig. 1. The occurrence of
slippage between the gas and liquid phases and
complex flow patterns introduced complications that
FLOW FLOW FLOW required development of new concepts.
Fig. 1-Flow patterns for upward vertical tlow. Two different approaches are commonly used to
develop predictive tools for describing complex fluid-
mechanics problems. The emprica! approach involves
properly selecting optimum pipe diameters to connect developing simplified models containing parameters
reservoirs with surface facilities, has followed a very that must be evaluated with experimental data.
logical history. Tracing this history requires a review Correlating variables typically are dimensionless
of three separate but interrelated topics. The first groups determined by performing a dimensional
involves understanding the basic fluid mechanics analysis of the phenomena involved. A classic
required to predict the interactions between the gas example of this for single-phase fluid flow is the
and liquid phases and the pressure drop. In general, Moody4 diagram, in which friction factors are
this involves developing expressions for conservation correlated as a function of Reynolds number and
of mass and linear momentum. Applying pressure- relative roughness for turbulent flows. The empirical
drop equations requires the ability to predict the approach does not address why or how things
physical properties of the gas and liquid phases. Thus happen, but can yield excellent results quickly,
the second topic is phase behavior. Finally, prediction depending on the proper selection of variables and the
of phase behavior also requires the ability to predict quality of data used for the correlation. The second
flowing temperatures of the fluids in a well. approach involves developing physically based
Temperature prediction involves applying the mechanistic models that describe ali important
principie of conservation of energy. The following phenomena. This requires much more in-depth
sections describe the historical development of each understanding and longer-term research.
of these tools, together with a brief description of The first and perhaps only exhaustive dimensional
attempts to evaluate the numerous correlations and analysis of the multiphase-flow-in-pipe problem was
models that have been developed. performed by Duns and Ros. 5 They identified 13
important variables, resulting in I O independent
Early Homogeneous Methods. From an international dimensionless groups that might be important in
perspective, most of the wells discovered in the early describing multiphase-flow behavior. After obtaining
fields were capable of flowing at extremely high flow extensive experimental data, they concluded that four
rates. The degree of turbulence in the wells was of these dimensionless groups were important for
sufficiently high for multiphase fluids to exist as predicting flow pattern and degree of slippage at any
homogeneous mixtures. Thus the gas and liquid location in vertical pipe. The degree of slippage
traveled at essentially the same velocity. Pressure- determines the fraction of pipe volume occupied by
gradient equations, such as Eq. 1, were a logical first liquid, a variable they called "Iiquid holdup." Most
attempt to describe multiphase flow; steady-state subsequent developers of emprica! correlations made
use of Duns and Ros' dimensional analysis.
single-phase-flow equations were modified by
The first attempt to obtain a large quantity of high-
replacing flow and physical property variables with
quality field-scale multiphase-flow data in vertical
mixture variables.
pipes was conducted by Hagedorn and Brown. 6
Using severa! different liquids and three different
dp Pmg sin() mPmVm 2 p111v111dv111
diameters of pipe, they flowed fluids up a 1,400-ft
..... (1)
dl ge Zdg gcdl [427-m] -deep vertical test well. At the time, the

16 Journal of Petroleum Technology, January 1987


importance of liquid holdup was not recognized and
they failed to measure this important variable. They 100.0-------------....
were forced to back-calculate liquid holdup using an
assumed pressure-gradient model. The resultant
ernpirical correlation developed for predicting these
pseudoholdups can give physically unrealistic values
that suggest that liquid flows faster than gas.
Although the Hagedorn and Brown correlation was
not flow-pattern dependent, numerous modifications --
o::
to this correlation have been made to improve
- ..J
pressure-drop predictions. (1) 1.0
Increases in exploration and production activity > <t
..J
offshore during the 1960' s resulted in the drilling of a ::,
z
large number of wells with large deviations in z
c:x:
inclination angle from the vertical. It soon became 0.1
obvious that flow-pattern and liquid-holdup prediction
methods developed for vertical flow often failed in 1.0 10.0
directional wells. The Beggs and Brill 7 and the
V (ft/s)
Mukherjee and Brill 8 generalized correlations were Sg
developed to improve pressure-drop predictions in
directional wells and hilly-terrain pipelines. 100.0 500.0
Concurrent with the development of the early Fig. 2-Taitel et al. flow pattern maps for air and water at
generalized emprica! correlations, many researchers atmospheric conditions.
were also investigating specific phenomena related to
multiphase flow, such as gas-bubble rise velocity and
mechanisms for flow-pattern transitions. A group of vertical upward flow in two different pipe diameters
generalized emprica! correlations that also made use using the Taitel et al. model. This model clarified the
of early mechanistic models were developed by discrepancy of the bubble/slug flow-pattern transition
Orkiszewski, 9 Chierici et al., 10 Aziz et al., 11 and that existed among various investigators by
Asheim. 12 Most of these studies made extensive use confirming that the existence of bubble flow is
of the work of Griffith and Wallis 13 and Nicklin diameter dependent. Once a reliable flow-pattern
et al. 14 . model is available, improved models can be
developed for describing the fundamental mechanisms
Mechanstic Models. Generalized empirical in each of the specific flow patterns.
correlations simply do not address the complex By far the most important flow patterns for
physical phenomena occurring during multiphase flow multiphase flow in wells are the slug and churn flow
in pipes. Consequently, an impasse has been reached patterns. These intermittent-flow patterns will occur
in which, regardless of the modifications that are during the vast majority of multiphase flow in wells.
made in empirical correlations or the amount of data Comprehensive slug flow models have been
used to develop the correlations, it is unlikely that developed by Fernandez et al., 19 Orell and
design calculations can improve. Application of Rembrand, 20 and Taitel. 21
empirical correlations to a broad range of data Bubble flow probably exists over only very short
typically results in errors in the range of 20% in lengths of pipe in an oil well. The mechanisms of
pressure-drop prediction. bubble flow have been studied extensively by Zuber
Recently, significant improvements have been made and Findlay, 22 Wallis, 23 and Harmathy. 24
in our ability to observe, study, and mathematically Perhaps the most difficult flow pattern to study,
model the physical mechanisms governing multiphase- and one that is probably most commonly encountered
flow behavior in pipe. The mechanistic model in gas wells producing water and/or condensare, is
approach incorporates ali important variables. the annular flow pattern. The prediction of liquid
Coupled with appropriate laboratory and field data, entrainment and interfacial phenomena is extremely
this approach will yield prediction methods that complex and is the subject of numerous studies
represent significant improvements over generalized currently under way.
emprica! correlations. Only two attempts have been made to develop
The first step in developing mechanistic models comprehensive pressure-drop models for wells that
must involve the prediction of flow patterns. Only incorporate or modify existing mechanistic models.
then can improved models be developed to predict, Caetano25 investigated vertical multiphase flow in
for each flow pattern, liquid holdup, interfacial shear concentric and fully eccentric annuli. This
stresses, and, consequently, pressure drop. Major configuration is commonly encountered in high-
breakthroughs in modeling flow patterns for wells productivity wells and in wells produced with sucker
have been published by Taitel et al. 15 and Barnea et rod pumps. For these cases, the multiphase mixture
al. 16-18 These comprehensive flow-pattern prediction flows up the annular space between the casing and
models can then be used to generate simple maps that tubing or between the tubing and sucker rods. Hasan
graphically demonstrate the relative importance of and Kabir26 developed similar models for multiphase
variables. Fig. 2 shows two such maps generated for tlow in vertical oil wells. No studies have been

Journal of Petroleum Technology, January 1987 17


negligible. In most cases, this assumption causes an
insignificant error in prediction of liquid density.
BUBBLE POINT
OR DISSOLVED SINGLE Prediction of the apparent viscosity of an oil/water
3500 GAS PHASE mixture, however, is not a trivial problem. Oil/water
RESERVOIRS GAS
RESERVOIRS mixtures typically behave as non-Newtonian fluids
<t and often exist in the form of ernulsions, with the
(/)
a. continuous phase having a dominant effect on the
w2500 DEW rheological behavior. Fortunately, friction losses are
POINT
a:: relatively minor in wellbores, and in most cases the
=>
(/)
selection of a liquid viscosity model has negligible
(/) effect on pressure drop.
w
8: 1500 Temperature Prediction. Fluid physical properties
are all temperature-dependent. Consequently, accurate
prediction of pressure drop and other flow variables
requires the ability to calculate temperature behavior
5000!"---oo----003-oo-' in wells simultaneously with pressure behavior. This is
also necessary to predict the presence of other
TEMPERATURE, F potential problems, such as wax formation, hydrates,
Fig. 3-Pressure/temperature phase diagram of a reser-
and other possible detrimental effects, such as melting
voir fluid. of permafrost in arctic regions.
All the early pressure-drop calculation procedures
used the black oil model for predicting fluid physical
published on similar models for flow in directional or properties. Because physical properties for
inclined wells, bubblepoint or dissolved-gas reservoirs vary
uniformly with temperature, it was not uncommon
Fluid Physical Properties. Ali procedures for simply to assume a linear temperature gradient in
calculating pressure drop for the multiphase flow of wellbores. This required assuming a flowing wellhead
multicomponent fluids require methods to predict ternperature, which may not be representative, and
mass transfer between the gas and liquid phases and totally ignored the complex heat-transfer mechanisms
physical properties of each phase. Two types of mass- that exist in wells. Vigorous calculation of
transfer models have been used frequently in the temperatures requires application of conservation-of-
petroleum industry, depending on the composition of energy principies, resulting in a heat balance
the fluid mixture and the range of reservoir equation:
temperature encountered. These methods are referred
to as the "black oil" model and the "compositional" dh dQ g sin 8 Vm dv.,
model approaches. Fig. 3 shows a typical ............. (2)
pressure/temperature diagram of a reservoir fluid. dL dL J J dL
The simplified black oil model is typically used for
bubble-point or dissolved-gas-type reservoir fluids. Brill and Beggs 27 described a computing algorithm
On the other hand, compositional models are better that permitted coupling pressure-drop calculations
suited for predicting behavior of dewpoint or with the heat-balance equation using a finite-
retrograde gas-condensate reservoirs. Compositional difference numerical approximation. An approach like
models are more complex than black oil models and this normally is required for simulating wells
are best suited for modeling mass transfer when fluids producing from dewpoint or retrograde gas-
exhibit retrograde condensation behavior. Regardless condensate reservoirs. Ramey28 developed an .
of the phase behavior model used, it is vitally analytical approximation to Eq. 2 that accounted for
important that a reliable prediction be made on the the transient heat-conduction effects from heating the
fractions of total fluid existing in the gas and liquid rocks surrounding a wellbore. Shiu and Beggs29
phases. developed a semiempirical correlation for one of the
In addition to mass-transfer effects, it is necessary parameters in the Ramey equation that simplified the
to have reliable predictions for the density, viscosity, computation procedure. Both of these analytical
and surface tension of each phase. Empirical approximations neglect Joule-Thompson effects,
correlations are available for these properties, but which could be important in high-flow-rate gas wells.
laboratory data should be used ifavailable.
Unfortunately, these data are seldom measured or Evaluation Studies. The number and diversity of
are available at only a few temperatures, or perhaps correlations and models available for predicting
only one. multiphase-flow behavior in wells are overwhelming
Prediction of frictional pressure losses for to most engineers. lt is not always possible or
multiphase flow involving gas, oil, and water remains affordable to perform simulation studies with several
an unsolved problem. The oil and water phases are of the methods available. Numerous evaluation studies
normally combined into a single liquid phase, even have been performed in which the various methods
though the liquid phases are immiscible. Slippage are applied to selected sets of data and conclusions
between the oil and water phases is assumed to be drawn pertaining to the relative accuracies. Serious
18 Journal of Petroleum Technology, January 1987
TO
SEPARATOR- o
o 20 24 21
,1usu11 In 100 ,s1G

(ALL OIL)
Tubii, Size 4 in. l.D.
Producint Rale !000 Bbls./D,y
Oil AP1 Gmity 35' API
G.as Specific G,avity 11.&5
Aver.11e Flowint Temp. 140' F

Fig. 4-Severe slug formation in a pipeline/riser-pipe


system.
o
o
o
' limitations of these studies arise because of the !
limited size and accuracy of the data and the limited
range of important variables that exist in available
data banks. In addition, many evaluation studies
compare statistical results of a proposed correlation
with other correlations when applied to the same data
used to develop the proposed correlation. Conclusions
drawn are obviously biased. Impartial evaluation
studies include those by Lawson and Brill, 30 Esanol
et al., 31 Gregory et al. , 32 Reinicki and Remer, 3
and Kabir and Hassan. 34 The only legitimate
conclusion that can be drawn from this collection of
evaluation studies is that no best method is currently 10
available to the engineer. lt thus becomes necessary
to have several methods available for comparative
purposes, and one should not be surprised if a Fig. 5-Example of vertical multiphase flow pressure gra-
method that works best for one type of fluid does not dient curves.
work nearly as well for other fluids. Finally, it is
absolutely necessary to recognize that errors in
pressure-drop prediction can easily be caused by calculations. Spacing of gas lift valves and
errors in prediction of fluid physical properties rather determination of optimum injection gas volumes
than inadequate prediction of phenomena such as flow require use of steady-state multiphase-flow pressure-
patterns, slippage, or liquid holdup. loss predictions. The same is true of determining the
type, location, size, and power requirements of
Applications downhole pumps. Analysis of well tests in many
Numerous applications have made use of the pumping wells requires converting casinghead
developments presented in the previous section. pressures to bottomhole pressures for a system in
Essentially every technical paper pertaining to the which gas percolates through a static liquid column in
production of oil and gas in the literature involves the annulus. Detailed descriptions of the application
one of these applications. A thorough discussion of of multiphase flow in artificial lift design can be
ali applications is beyond the scope of this paper. found in Refs. 38 and 39.
Sorne of the more important applications are
described below. An exhaustive literature search on Severe Slugging in Pipelne/Riser-Ppe Systems. A
these topics would fill pages, so only selected unique phenomenon involving vertical multiphase
references are given. flow can occur in riser pipes at offshore platforms
when the incorr:iing uis enter th riser pifce rom a
Total Production Systems Analysis. The concept of downward-sloping pipeline. Schmidt et al. 0 first
using correlations to predict multiphase-flow behavior observed the occurrence of this phenomenon over a
through pipes, well completions, restrictions, and the limited range of gas and liquid flow rates in which
reservoir for analysis of flow behavior in the entire stratified flow would normally occur in the pipeline.
production system has been recognized for more than These flow rates would exist in oversized pipelines or
20 years. 35,36 This approach, often called nodal late in the life of an offshore ol field. Severe
analysis, was the subJect of another Distinguished slugging is a cyclical process in which the riser pipe
Author Series paper. 7 The objective of nodal periodically fills with liquid, temporarily stops the
analysis is to optimize design calculations for ol and flow of gas up the riser pipe, and creates a slug of
gas wells. This permits evaluation of the interactions liquid in both the riser pipe and the upstream
of individual components in the production system. pipeline. The process of liquid slug generation is
shown in Fig. 4. This is an undesirable phenomenon
Artificial Lift. The design of ali artificial lift that can cause problems related to pipe stresses and
procedures involves use of multiphase flow in pipe poor separator behavior.

Joumal of Petroleum Technology, January 1987 19


These operating problems have resulted in to one in which governing phenomena can be
numerous studies to describe flow behavior during modeled with basic principies.
severe slugging. 2140-43 A large-scale test facility was
constructed in Norway to investigate the problem in Nomenclature
larger-diameter pipe and at higher pressures. 44 d = interna! pipe diameter, ft [m]
Attempts to alleviate severe slugging by choking or f = friction factor
gas-lifting the riser pipe are being pursued. g = acceleration of gravity, ft/sec2 [m/s2 ]
h = enthalpy, Btu/lbm [J/kg]
Pressure-Gradient Curves. Sizing of tubing and J = mechanical equivalent of heat, 778
design of continuous gas lift installations are
ft-lbf/Btu
frequently accomplished through the use of pressure-
gradient curves. Indeed, entire books of gradient L = pipe length, ft [m]
curves have been developed to permit this practice. 38 LE = distance from pipeentrance, ft [m]
Fig. 5 shows the resultant gradient curves for a p = pressure, psi [kPa]
specific set of flowing conditions. Use of gradient Q = heat transferred from fluid to surroundings,
curves involves serious limiting assumptions, Btu/lbm [J/kg]
including vertical flow, fluid properties based on T = temperature, F [C]
specified fluid specific gravities, and selection of one v = velocity, ft/sec [m/s]
multiphase-flow correlation. These limitations, () = pipe inclination angle from horizontal,
coupled with the increased availability of technical degrees
software for personal computers, should result in a p = density, lbm/ft ' [kg/m3]
sharp decline in the use of gradient curves in the
future. Subscripts
g = gas
Production Logging. The modern concept of L = liquid
production logging involves lowering various m = two-phase mixture
measurement tools into a producing or injecting S = superficial
wellbore to obtain measurements that will permit
evaluation of well performance. Typical References
measurements include temperatures, radioactive tracer l. Poettmann, F.H. and Carpenter, P.G.: "The Multiphase Flow of
surveys, noise logs, spinner flowmeters, percent Gas, Oil and Water Through Vertical Flow Strings with Application
water measurements, and fluid density measurements. to the Design of Gas Lift Installations," Drill, and Prod. Prac.,
Although production logging is an accepted practice, API (1952) 257-317.
interpretation of measurements often fails because of 2. Baxendell, P.B. and Thomas, R.: "The Calculation of Pressure
Gradients in High-Rate Flowing Wells," JPT(Oct. 1961) 1020-28;
indequate understanding of multiphase-flow Trans., AIME, 222.
phenomena. Hill and Oolman45 confirmed that 3. Fancher, G.H. Jr. and Brown, K.E.: "Prediction of Pressure
multiphase-flow behavior in inclined wells often Gradients for Multiphase Flow in Tubing," SPEJ (March 1963)
results in misleading tool responses. 59-69; Trans., AIME, 231.
4. Moody, L.F.: "Friction Factors for Pipe Flow," Trans., ASME
(Nov. 1944) 66, No. 8, 671-84.
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often produced in unsteady-state, cyclic processes that Mixtures in Wells," Proc., Sixth World Petroleum
result in a time-dependent flow rate of gas and liquid. Congress, Frankfurt (1963) 11, 451-65.
6. Hagedom, A.R. and Brown, K.E.: "The Effect of Liquid Viscosity
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intermittent gas lift, wells that are undergoing a AIME, 231.
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Inclined Pipes," JPT(May 1973) 607-17; Trans., AIME, 255.
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Journal of Petroleum Technology, January 1987
20
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Annual Technical Conference and Exhibition, Houston, Sept. psi X 6.894 757 E+OO kPa
16-19. scf/bbl X 1.801 175 E-01 std m3/m3
34. Kabir, C.S. and Hasan, A.R.: "A Study of Multiphase Flow
Behavior in Vertical Oil Wells: Part ll-Field Application," paper
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Oakland, April 2-4. "'Conversion factor is exact. JPT
35. Nind, T.E.W.: Principies of Oil We/1 Production, McGraw-Hill
This paper is SPE 16242. Distinguished Author Series articles are general, descrip-
Book Co. !ne., New York City (1964).
tiva presentations that summarize the state of the art in an area of technology by describ-
, 36. Brill, J.P. et al.: "Practica! Use ofRecent Research in Multiphase ing recen! developments for readers who are not specialists in the tapies discussed.
Vertical and Horizontal Flow," JPT (April 1966) 502-12; Trans., Written by individuals recognized as experts in the area. these articles provide key
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technology. Purpose: To inform the general readership ofrecen! advances in various
37. Brown, K.E. and Lea, J.F.: "Nodal Systems Analysisofil and areas of petroleum engineering. A softbound anthology. SPE Distinguished Author Ser-
Gas Wells," JPT(Oct. 1985) 1751-63. ies, Dec. 1981-Dec. 1983, is available from SPE's Book Order Dept.

Journal of Petroleum Technology, January 1987 21

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