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Lu_31_ICGCM_MassiveSandstoneChannel_5

The document summarizes efforts to address challenges from mining through a massive sandstone channel using hydraulic fracturing and monitoring technologies. Hydraulic fracturing of boreholes was conducted ahead of the longwall face to relieve stresses. Numerical models and Longwall Visual Analysis (LVA) software were used to monitor stresses and predict caving. Daily face monitoring over 4 weeks showed correlations between observed conditions, frac locations, and LVA predictions, validating the approaches. Production increased significantly compared to a previous longwall panel without fracturing or monitoring.

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Daniel W.H. Su, Sr. geomechanical engineer Greg J. Hasenfus, Sr. geomechanical engineer Luke Stull, geologist Jun Lu, geomechanical engineer Mark Van Dyke, geologist Stephen Morgan, geologist Paul Kelley, mine engineer Don Teter, project engineer
Outline Introduction Objective Geology/Geologic Reconnaissance Hydro Frac Hole Locations and Frac Process Flac3D Models Longwall Visual Analysis (LVA) Monitoring Face Monitoring and Evaluation Conclusions
Introduction
Introduction Sandstone Intrusion Encountered During Development
Introduction Sandstone Intrusion Encountered During Development Base of Sandstone Channel
Introduction F20 Longwall Panel Problems  Delayed caving behind shield supports  Massive sandstone pot-outs in front of shields  Increased risk to personnel  Delayed Production Longwall production footage per week 344 24 106 306 371 338 230
Objective To evaluate the effectiveness of the hydraulic fracturing program and the validity of Longwall Visual Analysis (LVA) software to mitigate the impact of a 1, 000-foot (305-meter) wide massive sandstone channel on a 1,500-ft-wide (457-meter-wide) longwall face.
Geologic Reconnaissance  In-Mine Core Drilling  Stratascope Observations  In-Mine Mapping  Primary Stress Orientation  Rock Lab Testing Average Axial Compressive Strength 8283 psi
Geologic Reconnaissance Trough of Sandstone Channel at Wall # 29 Base of Sandstone INBY OUTBYWALL #33 WALL #27 Drawslate Pittsburgh Seam 5Feet Vertical Scale
Frac Hole Locations and Frac Stage Horizons
Frac Process Perforations were shot into the casing at the targeted horizons to pre- fracture the sandstone. The estimated shot penetration into the borehole surface was about 26 to 30 inches (0.66 to 0.76 meter).
Frac Process Water fracing was employed
Frac Process Fracing result Initial break Shut-in
Outline Introduction Objective Geology/Geologic Reconnaissance Hydro Frac Hole Locations and Frac Process Flac3D Models Longwall Visual Analysis (LVA) Monitoring Face Monitoring and Evaluation Conclusions
FLAC3D 3.10 Itasca Consulting Group, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 11503 Model Perspective 16:38:18 Thu Jul 26 2012 Center: X: 2.000e+000 Y: 3.860e+002 Z: 1.400e+001 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-After View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.9448e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 FLAC3D 3.10 Itasca Consulting Group, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 15221 Model Perspective 16:37:57 Thu Jul 26 2012 Center: X: 2.000e+000 Y: 2.138e+002 Z: 1.400e+001 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-Before View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.4037e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 Flac3D Model Without Frac Massive Sandstone Clayey Shale Longwall face FLAC3D 3.10 Itasca Consulting Group, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 15221 Model Perspective 14:55:06 Wed Jul 18 2012 Center: X: 1.585e+000 Y: 2.107e+002 Z: 8.023e+000 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-Before View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.9448e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 Massive Sandstone Clayey Shale Longwall face Shear stress, psi With Frac Frac horizon 15 ft
Longwall Visual Analysis (LVA) LVA was installed to track the face pressure and cavity formation index. Cavity Risk Index (CRI)
Face Monitoring and Evaluation To evaluate the effectiveness of the hydraulic fracturing program and the validity of LVA software, daily face monitoring over a 4-week period was conducted. Based on the collected information, the correlations among the observed face conditions, the hydro frac hole locations and the LVA cavity formation prediction were analyzed. Underground Observation Hydraulic Fracturing Longwall Visual Analysis
Ming Direction
Dec. 20, 2011
Face Monitoring and Evaluation
Face Monitoring and Evaluation
Face Monitoring and Evaluation Longwall production footage per week 240 124 232 142 115 194 323 F21—SS fraced 344 24 106 306 338 230 F20—SS not fraced
Conclusions Successful application of hydraulic fracturing technique. Successful application of LVA software. Improve safety and increase productivity.
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Lu_31_ICGCM_MassiveSandstoneChannel_5

  • 1.
    Daniel W.H. Su,Sr. geomechanical engineer Greg J. Hasenfus, Sr. geomechanical engineer Luke Stull, geologist Jun Lu, geomechanical engineer Mark Van Dyke, geologist Stephen Morgan, geologist Paul Kelley, mine engineer Don Teter, project engineer
  • 2.
    Outline Introduction Objective Geology/Geologic Reconnaissance Hydro FracHole Locations and Frac Process Flac3D Models Longwall Visual Analysis (LVA) Monitoring Face Monitoring and Evaluation Conclusions
  • 3.
  • 4.
  • 5.
    Introduction Sandstone Intrusion EncounteredDuring Development Base of Sandstone Channel
  • 6.
    Introduction F20 Longwall PanelProblems  Delayed caving behind shield supports  Massive sandstone pot-outs in front of shields  Increased risk to personnel  Delayed Production Longwall production footage per week 344 24 106 306 371 338 230
  • 7.
    Objective To evaluate theeffectiveness of the hydraulic fracturing program and the validity of Longwall Visual Analysis (LVA) software to mitigate the impact of a 1, 000-foot (305-meter) wide massive sandstone channel on a 1,500-ft-wide (457-meter-wide) longwall face.
  • 8.
    Geologic Reconnaissance  In-MineCore Drilling  Stratascope Observations  In-Mine Mapping  Primary Stress Orientation  Rock Lab Testing Average Axial Compressive Strength 8283 psi
  • 9.
    Geologic Reconnaissance Trough of Sandstone Channelat Wall # 29 Base of Sandstone INBY OUTBYWALL #33 WALL #27 Drawslate Pittsburgh Seam 5Feet Vertical Scale
  • 10.
    Frac Hole Locationsand Frac Stage Horizons
  • 11.
    Frac Process Perforations wereshot into the casing at the targeted horizons to pre- fracture the sandstone. The estimated shot penetration into the borehole surface was about 26 to 30 inches (0.66 to 0.76 meter).
  • 12.
  • 13.
  • 14.
    Outline Introduction Objective Geology/Geologic Reconnaissance Hydro FracHole Locations and Frac Process Flac3D Models Longwall Visual Analysis (LVA) Monitoring Face Monitoring and Evaluation Conclusions
  • 15.
    FLAC3D 3.10 Itasca ConsultingGroup, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 11503 Model Perspective 16:38:18 Thu Jul 26 2012 Center: X: 2.000e+000 Y: 3.860e+002 Z: 1.400e+001 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-After View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.9448e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 FLAC3D 3.10 Itasca Consulting Group, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 15221 Model Perspective 16:37:57 Thu Jul 26 2012 Center: X: 2.000e+000 Y: 2.138e+002 Z: 1.400e+001 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-Before View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.4037e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 Flac3D Model Without Frac Massive Sandstone Clayey Shale Longwall face FLAC3D 3.10 Itasca Consulting Group, Inc. Minneapolis, MN USA ©2006 Itasca Consulting Group, Inc. Step 15221 Model Perspective 14:55:06 Wed Jul 18 2012 Center: X: 1.585e+000 Y: 2.107e+002 Z: 8.023e+000 Rotation: X: 0.000 Y: 0.000 Z: 90.000 Dist: 1.361e+003 Mag.: 18.2 Ang.: 22.500 Job Title: F-21 Sandstone Frac-Before View Title: Zone Extra 1 Magfac = 1.000e+000 Live mech zones shown Gradient Calculation 1.9448e+002 to 5.0000e+002 5.0000e+002 to 1.0000e+003 1.0000e+003 to 1.5000e+003 1.5000e+003 to 2.0000e+003 2.0000e+003 to 2.5000e+003 2.5000e+003 to 3.0000e+003 3.0000e+003 to 3.5000e+003 3.5000e+003 to 4.0000e+003 4.0000e+003 to 4.3785e+003 Interval = 5.0e+002 Massive Sandstone Clayey Shale Longwall face Shear stress, psi With Frac Frac horizon 15 ft
  • 16.
    Longwall Visual Analysis(LVA) LVA was installed to track the face pressure and cavity formation index. Cavity Risk Index (CRI)
  • 17.
    Face Monitoring andEvaluation To evaluate the effectiveness of the hydraulic fracturing program and the validity of LVA software, daily face monitoring over a 4-week period was conducted. Based on the collected information, the correlations among the observed face conditions, the hydro frac hole locations and the LVA cavity formation prediction were analyzed. Underground Observation Hydraulic Fracturing Longwall Visual Analysis
  • 18.
  • 19.
  • 20.
  • 21.
  • 23.
    Face Monitoring andEvaluation Longwall production footage per week 240 124 232 142 115 194 323 F21—SS fraced 344 24 106 306 338 230 F20—SS not fraced
  • 24.
    Conclusions Successful application ofhydraulic fracturing technique. Successful application of LVA software. Improve safety and increase productivity.
  • 25.