The current perspective of the PA 1957 gas well pillar study and its implications for longwall gas well pillars

Many states rely upon the Pennsylvania 1957 Gas Well Pillar Study to evaluate the coal barrier surrounding gas wells. The study included 77 gas well failure cases that occurred in the Pittsburgh and Freeport coal seams over a 25-year span. At the time, coal was mined using the room-and-pillar mining method with full or partial pillar recovery, and square or rectangle pillars surrounding the gas wells were left to protect the wells. The study provided guidelines for pillar sizes under different overburden depths up to213 m(700 ft). The 1957 study has also been used to determine gas well pillar sizes in longwall mines since longwall mining began in the 1970 s. The original study was developed for room-and-pillar mining and could be applied to gas wells in longwall chain pillars under shallow cover. However, under deep cover, severe deformations in gas wells have occurred in longwall chain pillars. Presently, with a better understanding of coal pillar mechanics, new insight into subsidence movements induced by retreat mining, and advances in numerical modeling, it has become both critically important and feasible to evaluate the adequacy of the 1957 study for longwall gas well pillars. In this paper, the data from the 1957 study is analyzed from a new perspective by considering various factors, including overburden depth, failure location, failure time, pillar safety factor(SF), and floor pressure. The pillar SF and floor pressure are calculated by considering abutment pressure induced by full pillar recovery. A statistical analysis is performed to find correlations between various factors and helps identify the most significant factors for the stability of gas wells influenced by retreat mining. Through analyzing the data from the 1957 study, the guidelines for gas well pillars in the 1957 study are evaluated for their adequacy for roomand-pillar mining and their applicability to longwall mining. Numerical modeling is used to model the stability of gas wells by quantifying the mining-induced stresses in gas well casings. Results of this study indicate that the guidelines in the 1957 study may be appropriate for pillars protecting conventional gas wells in both room-and-pillar mining and longwall mining under overburden depths up to 213 m(700 ft),but may not be sufficient for protective pillars under deep cover. The current evaluation of the 1957 study provides not only insights about potential gas well failures caused by retreat mining but also implications for what critical considerations should be taken into account to protect gas wells in longwall mining.     

Longwall mining under gateroads and gobs of abandoned small mine

Due to the use of outdated mining technology or room and pillar mining process in small coal mines, the coal recovery ratio is only 10–25%. In many regions of China, the damage area caused by the small coal mines amounted to nearly one hundred square kilometers. Therefore, special mining techniques must be taken to reclaim the wasted resource in disturbed coal areas. This paper focuses on the different mining methods by analyzing the longwall panel layout and abandoned gateroad(AG) distribution in the abandoned area of Cuijiazhai coal mine in northwestern China. On the basis of three-dimensional geological model, FLAC3 D numerical simulation was employed. The abutment pressure distribution was simulated when the panel face passed through the disturbed areas. The proper angle of the inclined face was analyzed when the panel face passed through the abandoned gateroads. The results show that the head end of the face should be 13–20 m ahead of the tail end. The pillars on both sides of abandoned gateroads had not been damaged at the same time, and no large-area stress concentration occured above the main roof.Therefore, the coal reserves of disturbed areas can be successfully recovered by using underground longwall mining.     

Coal bursts that occur during development: A rock mechanics enigma

Coal bursts are typically associated with highly stressed coal.Most bursts occur during retreat mining(longwall mining or pillar recovery) in highly stressed locations like the tailgate corner of the longwall panel.Others are associated with multiple seam interactions.However, a small but significant percentage of coal bursts have occurred during development or in outby locations unaffected by active mining.Most development bursts have been relatively small, but some have been highly destructive.No theory of coal bursts can be complete if it does not account for this type of event.This paper focusses on the development mining coal burst experience in the US, putting it into the context of the entire US coal burst database.The first documented development coal burst occurred almost exactly 100 years ago during slope drivage at the Sunnyside Mine in Utah.Sunnyside subsequently had a long history of bursts, mainly during retreat mining but also during development.Several Colorado mines have also experienced multiple development bursts.Many, but by no means all, of the development bursts in these western US coalfields have been associated with known faults.In the Central Appalachian coalfields, most development bursts have occurred in multiple seam situations.In some of these cases, however, there was no retreat mining in either seam.The paper closes with some lessons from this history, with implications for preventing such events in the future.     

Geotechnical considerations for concurrent pillar recovery in close-distance multiple seams

Room-and-pillar mining with pillar recovery has historically been associated with more than 25% of all ground fall fatalities in underground coal mines in the United States.The risk of ground falls during pillar recovery increases in multiple-seam mining conditions.The hazards associated with pillar recovery in multiple-seam mining include roof cutters, roof falls, rib rolls, coal outbursts, and floor heave.When pillar recovery is planned in multiple seams, it is critical to properly design the mining sequence and panel layout to minimize potential seam interaction.This paper addresses geotechnical considerations for concurrent pillar recovery in two coal seams with 21 m of interburden under about 305 m of depth of cover.The study finds that, for interburden thickness of 21 m, the multiple-seam mining influence zone in the lower seam is directly under the barrier pillar within about 30 m from the gob edge of the upper seam.The peak stress in the interburden transfers down at an angle of approximately 20°away from the gob, and the entries and crosscuts in the influence zone are subjected to elevated stress during development and retreat.The study also suggests that, for full pillar recovery in close-distance multiple-seam scenarios,it is optimal to superimpose the gobs in both seams, but it is not necessary to superimpose the pillars.If the entries and/or crosscuts in the lower seam are developed outside the gob line of the upper seam,additional roof and rib support needs to be considered to account for the elevated stress in the multiple-seam influence zone.     

User-friendly finite element design of main entries,barrier pillars,and bleeder entries

This contribution describes development and application of a user-friendly finite element program,UT3PC, to address three important problems in underground coal mine design:(1) safety of main entries,(2) barrier pillar size needed for entry protection, and(3) safety of bleeder entries during the advance of an adjacent longwall panel.While the finite element method is by far the most popular engineering design tool of the digital age, widespread use by the mining community has been impeded by the relatively high cost of and the need for lengthy specialized training in numerical methods.Implementation of UT3PC overcomes these impediments in three easy steps.First, a material properties file is prepared for the considered site.Next, mesh generation is automatic through an interactive process.A third and last step is simply execution of the program.Examples using data from several western coal mines illustrate the ease of using the application for analysis of main entries, barrier pillars, and bleeder entry safety.     

Fundamentals of modern ground control management in Australian underground coal mines

Underground coal mining is inherently hazardous, with uncontrolled ground failure regarded as one of only several critical risks for multiple fatality events. Development, implementation and management of overarching systems and procedures for maintaining strata control is an important step to mitigating the impact of ground failure hazards at a mine site operational level. This paper summarised the typical pro-active ground control management system(PGCMS) implemented in various Australian underground coal mines. Australia produces approximately 100 million tonnes a year of metallurgical and thermal coal from approximately 30 of the world's safest longwall mines operating in New South Wales and Queensland. The increased longwall productivity required to achieve both high levels of safety and profitability, places significant emphasis on the reliability of pro-active ground control management for longwall mining operations. Increased depths, adverse geological conditions, elevated variable stress regimes and weaker ground conditions, coupled with an industry wide need for increased development rates continue to make ground control management challenging. Ground control management is not only about ground support and pillar design though but also a structured process that requires a coordinated effort from all levels of the workforce to both minimise the occurrence of adverse geotechnical events and mitigate the potential risks when they do occur. The PGCMS presented in this paper is proven to provide both a safer and more productive mine environment through minimisation of unplanned delays. The critical elements of the method are presented in detail and demonstrate the utility and value of a ground control management system that has potential for implementation in underground coal mining globally.     

Effect of longwall-induced subsurface deformations on shale gas well casing stability under deep covers

This paper presents the results of a 2017 study conducted by the National Institute for Occupational Safety and Health(NIOSH), Pittsburgh Mining Research Division(PMRD), to evaluate the effects of longwall-induced subsurface deformations within a longwall abutment pillar under deep cover. The 2017 study was conducted in a southwestern Pennsylvania coal mine, which extracts 457 m-wide longwall panels under 361 m of cover. One 198 m-deep, in-place inclinometer monitoring well was drilled and installed over a 45 m by 84 m center abutment pillar. In addition to the monitoring well, surface subsidence measurements and underground coal pillar pressure measurements were conducted as the 457 m-wide longwall panel on the south side of the abutment pillar was being mined. Prior to the first longwall excavation, a number of simulations using FLAC3D~(TM) were conducted to estimate surface subsidence, increases in underground coal pillar pressure, and subsurface horizontal displacements in the monitoring well. Comparisons of the pre-mining FLAC3D simulation results and the surface, subsurface,and underground instrumentation results show that the measured in-place inclinometer casing deformations are in reasonable agreement with those predicted by the 3D finite difference models. The measured surface subsidence and pillar pressure are in excellent agreement with those predicted by the 3D models.Results from this 2017 research clearly indicate that, under deep cover, the measured horizontal displacements within the abutment pillar are approximately one order of magnitude smaller than those measured in a 2014 study under medium cover.     

Analysis of coal pillar stability(ACPS): A new generation of pillar design software

Thirty years ago, the analysis of longwall pillar stability(ALPS) inaugurated a new era in coal pillar design.ALPS was the first empirical pillar design technique to consider the abutment loads that arise from full extraction, and the first to be calibrated using an extensive database of longwall mining case histories.ALPS was followed by the analysis of retreat mining stability(ARMPS) and the analysis of multiple seam stability(AMSS). These methods incorporated other innovations, including the coal mine roof rating(CMRR), the Mark-Bieniawski pillar strength formula, and the pressure arch loading model. They also built upon ever larger case history databases and employed more sophisticated statistical methods.Today, these empirical methods are used in nearly every underground coal mine in the US. However,the piecemeal manner in which these methods have evolved resulted in some weaknesses. For example,in certain situations, it may not be obvious which program is the best to use. Other times the results from the different programs are not entirely consistent with each other. The programs have also not been updated for several years, and some changes were necessary to keep pace with new developments in mining practice. The analysis of coal pillar stability(ACPS) now integrates all three of the older software packages into a single pillar design framework. ACPS also incorporates the latest research findings in the field of pillar design, including an expanded multiple seam case history data base and a new method to evaluate room and pillar panels containing multiple rows of pillars left in place during pillar recovery.ACPS also includes updated guidance and warnings for users and features upgraded help files and graphics.     

A coal rib monitoring study in a room-and-pillar retreat mine

The National Institute for Occupational Safety and Health(NIOSH) conducted a comprehensive monitoring program in a room-and-pillar mine located in Southern Virginia. The deformation and the stress change in an instrumented pillar were monitored during the progress of pillar retreat mining at two sites of different geological conditions and depths of cover. The main objectives of the monitoring program were to better understand the stress transfer and load shedding on coal pillars and to quantify the rib deformation due to pillar retreat mining; and to examine the effect of rib geology and overburden depth on coal rib performance. The instrumentation at both sites included pull-out tests to measure the anchorage capacity of rib bolts, load cells mounted on rib bolts to monitor the induced loads in the bolts, borehole pressure cells(BPCs) installed at various depths in the study pillar to measure the change in vertical pressure within the pillar, and roof and rib extensometers installed to quantify the vertical displacement of the roof and the horizontal displacement of the rib that would occur during the retreat mining process.The outcome from the monitoring program provides insight into coal pillar rib support optimization at various depths and geological conditions. Also, this study contributes to the NIOSH rib support database in U.S coal mines and provides essential data for rib support design.     

Effects of longwall-induced stress and deformation on the stability and mechanical integrity of shale gas wells drilled through a longwall abutment pillar

This paper presents the results of a comprehensive study conducted by CONSOL Energy, Marcellus Shale Coalition, and Pennsylvania Coal Association to evaluate the effects of longwall-induced subsurface deformations on the mechanical integrity of shale gas wells drilled over a longwall abutment pillar.The primary objective is to demonstrate that a properly constructed gas well in a standard longwall abutment pillar can maintain mechanical integrity during and after mining operations. A study site was selected over a southwestern Pennsylvania coal mine, which extracts 457-m-wide longwall faces under about 183 m of cover. Four test wells and four monitoring wells were drilled and installed over a 38-m by84-m centers abutment pillar. In addition to the test wells and monitoring wells, surface subsidence measurements and underground coal pillar pressure measurements were conducted as the 457-m-wide longwall panels on the south and north sides of the abutment pillar were mined by. To evaluate the resulting coal protection casing profile and lateral displacement, three separate 60-arm caliper surveys were conducted. This research represents a very important step and initiative to utilize the knowledge and science obtained from mining research to improve miner and public safety as well as the safety and health of the oil and gas industries.     

A review of the geomechanics aspects of a double fatality coal burst at Austar Colliery in NSW,Australia in April 2014

A coal burst occurred on 15 April, 2014 at the Austar Coal Mine, located west of Newcastle, NSW,Australia. The burst resulted in fatal injuries to two men working as part of the mining crew at the development face. At the time, a continuous miner was being used to mine a longwall development gate road through heavily structured coal, at a depth of approximately 550 m. A number of pre-cursor bumps had occurred on previous shifts, emanating from the coal ribs of the roadway, in proximity to the coal face.This paper reviews the geological, geotechnical and mining conditions and circumstances leading up to the coal burst event; and presents and discusses the available evidence and possible interpretations relating to the geomechanical behaviour mechanisms that may have been critical factors in this incident. The paper also discusses some key technical and operational considerations of ground support systems and mining practices and strategies needed for operating in such conditions in the future.     

A case study of the stability of a non-typical bleeder entry system at a U.S. longwall mine

Longwall abutment loads are influenced by several factors, including depth of cover, pillar sizes, panel dimensions, geological setting, mining height, proximity to gob, intersection type, and size of the gob.How does proximity to the gob affect pillar loading and entry condition? Does the gob influence depend on whether the abutment load is a forward, side, or rear loading? Do non-typical bleeder entry systems follow the traditional front and side abutment loading and extent concepts? If not, will an improved understanding of the combined abutment extent warrant a change in pillar design or standing support in bleeder entries? This paper details observations made in the non-typical bleeder entries of a moderate depth longwall panel—specifically, data collected from borehole pressure cells and roof extensometers,observations of the conditions of the entries, and numerical modeling of the bleeder entries during longwall extraction. The primary focus was on the extent and magnitude of the abutment loading experienced due to the extraction of the longwall panels. Due to the layout of the longwall panels and bleeder entries, the borehole pressure cells(BPCs) and roof extensometers did not show much change due to the advancing of the first longwall. However, they did show a noticeable increase due to the second longwall advancement, with a maximum of about 4 MPa of pressure increase and 5 mm of roof deformation. The observations of the conditions showed little to no change from before the first longwall panel extraction began to when the second longwall panel had been advanced more than 915 m. Localized pillar spalling was observed on the corners of the pillars closest to the longwall gob as well as an increase in water in the entries. In addition to the observations and instrumentation, numerical modeling was performed to validate modeling procedures against the monitoring results and evaluate the bleeder design.ITASCA Consulting Group's FLAC3 D numerical modeling software was used to evaluate the bleeder entries. The results of the models indicated only a minor increase in load during the extraction of the longwall panels. These models showed a much greater increase in stress due to the development of the gateroad and bleeder entries--about 80% development and 20% longwall extraction. The FLAC3 D model showed very good correlation between modeled and expected gateroad loading during panel extraction. The front and side abutment extent modeled was very similar to observations from this and previous panels.     

Influence of longwall mining on the stability of gas wells in chain pillars

Longwall mining has a significant influence on gas wells located within longwall chain pillars. Subsurface subsidence and abutment pressure induced by longwall mining can cause excessive stresses and deformations in gas well casings. If the gas well casings are compromised or ruptured, natural gas could migrate into the mine workings, potentially causing a fire or explosion. By the current safety regulations,the gas wells in the chain pillars have to be either plugged or protected by adequate coal pillars. The current regulations for gas well pillar design are based on the 1957 Pennsylvania gas well pillar study. The study provided guidelines for gas well pillars by considering their support area and overburden depth as well as the location of the gas wells within the pillars. As the guidelines were developed for room-andpillar mining under shallow cover, they are no longer applicable to modern longwall coal mining, particularly, under deep cover. Gas well casing of failures have occurred even though the chain pillars for the gas wells met the requirements by the 1957 study. This study, conducted by the National Institute for Occupational Safety and Health(NIOSH), presents seven cases of conventional gas wells penetrating through longwall chain pillars in the Pittsburgh Coal Seam. The study results indicate that overburden depth and pillar size are not the only determining factors for gas well stability. The other important factors include subsurface ground movement, overburden geology, weak floor, as well as the type of the construction of gas wells. Numerical modeling was used to model abutment pressure, subsurface deformations, and the response of gas well casings. The study demonstrated that numerical models are able to predict with reasonable accuracy the subsurface deformations in the overburden above,within, and below the chain pillars, and the potential location and modes of gas well failures, thereby providing a more quantifiable approach to assess the stability of the gas wells in longwall chain pillars.     

Coal rib response during bench mining: A case study

In 2016, room-and-pillar mining provided nearly 40% of underground coal production in the United States.Over the past decade, rib falls have resulted in 12 fatalities, representing 28% of the ground fall fatalities in U.S.underground coal mines.Nine of these 12 fatalities(75%) have occurred in room-andpillar mines.The objective of this research is to study the geomechanics of bench room-and-pillar mining and the associated response of high pillar ribs at overburden depths greater than 300 m.This paper provides a definition of the bench technique, the pillar response due to loading, observational data for a case history, a calibrated numerical model of the observed rib response, and application of this calibrated model to a second site.     

Longwall surface subsidence control by technology of isolated overburden grout injection

Surface subsidence is a typical ground movement due to longwall mining, which causes a series of environmental problems and hazards. In China, intensive coal extractions are commonly operated under dense-populated coalfields, which exacerbates the negative subsequences resulted from surface settlement. Therefore, effective approaches to control the ground subsidence are in urgent need for the Chinese coal mining industry. This paper presents a newly developed subsidence control technology: isolated overburden grout injection, including the theory, technique and applications. Relevant procedures such as injection system design, grouting material selection, borehole layout, grout take estimation and injection process design are proposed. The applicability of this technology has been demonstrated through physical modelling, field measurements, and case studies. Since 2009, the technology has been successfully applied to 14 longwall areas in 9 Chinese coal mines. The ultimate surface subsidence factors vary from 0.10 to 0.15. This method has a great potential to be popularized and performed where longwall mining are implemented under villages and ground infrastructures.     

Analysis of gateroad stability at two longwall mines based on field monitoring results and numerical model analysis

Coal mine longwall gateroads are subject to changing loading conditions induced by the advancing longwall face. The ground response and support requirements are closely related to the magnitude and orientation of the stress changes, as well as the local geology. This paper presents the monitoring results of gateroad response and support performance at two longwall mines at a 180-m and 600-m depth of cover.At the first mine, a three-entry gateroad layout was used. The second mine used a four-entry, yieldabutment-yield gateroad pillar system. Local ground deformation and support response were monitored at both sites. The monitoring period started during the development stage and continued during first panel retreat and up to second panel retreat. The two data sets were used to compare the response of the entries in two very different geotechnical settings and different gateroad layouts. The monitoring results were used to validate numerical models that simulate the loading conditions and entry response for these widely differing conditions. The validated models were used to compare the load path and ground response at the two mines. This paper demonstrates the potential for numerical models to assist mine engineers in optimizing longwall layouts and gateroad support systems.     

Numerical investigation into effect of rear barrier pillar on stress distribution around a longwall face

Numerical investigation was performed to examine the effect of rear barrier pillar on stress distribution around a longwall face. Salamon theoretical formula was used to calculate the parameters of the caving zone, which was later assigned to double yield constitutive model in FLAC3 D. Numerical results demonstrate that high stress concentration zone exists above the region where the second open-off cut intersects with the rear barrier pillar due to stress transfer and plastic zone expansion. It is also found that the maximum vertical stresses with varied distance to the seam floor are all within the projective plane of the rear barrier pillar and their positions concentrate on the barrier pillar adjacent to the connection corner of the second open-off cut. In addition, position of the maximum vertical stresses abruptly transfer from the connection corner adjacent to former panel to that adjacent to current panel along the panel direction.     

A semi-quantitative coal burst risk classification system

Safety is the highest priority in the mining industry as underground mining in particular poses high safety risks to its workers. In underground coal mines, coal bursts are one of the most catastrophic hazards, which involves sudden and violent dynamic coal mass failure with rapid ejection of the broken material into the mine workings. Despite decades of research, the contributing mechanisms of coal bursts are still not completely understood. Hence, it remains challenging to forecast coal bursts and quantify their likelihood of occurrence. However, a range of geological and geotechnical factors are associated with coal bursts and can increase the coal burst proneness. This paper introduces a semi-quantitative coal burst risk classification system, namely, BurstRisk. Based on back-analysis of case histories from Australia, China and the United States, BurstRisk classifies the coal burst risk into three categories:low, medium and high risk. In addition, it allows mining engineers to modify the weighting of the selected factors based on specific conditions. The risk classification charts introduced are for both longwall retreat and development sections of long-wall mining operations. This paper also provides a set of risk management strategies and control measures for effective coal burst mitigation.     

工作面支承压力分布的研究

为了研究采场支承压力,运用FLAC3D软件建立工作面开采数值模拟模型,研究了工作面前支承压力分布形态及应力峰值的位置,通过与理论计算、现场实测的结果相比较,得出数值模拟、理论分析、现场实测的结果是基本一致的,提出了采场前支承压力的计算方法,对井下工作面超前支护距离设计具有借鉴意义。     

Using LaModel to analyze coal bumps

Coal bumps have long been a safety hazard in coal mines, and even after decades of research, the exact mechanics that cause coal bumps are still not well understood. Therefore, coal bumps are still difficult to predict and control. The LaModel program has a long history of being used to effectively analyze displacements and stresses in coal mines, and with the recent addition of energy release and local mine stiffness calculations, the LaModel program now has greatly increased capabilities for evaluating coal bump potential. This paper presents three recent case histories where coal stress, pillar safety factor, energy release rate and local mine stiffness calculations in LaModel were used to evaluate the pillar plan and cut sequencing that were associated with a number of bumps. The first case history is a longwall mine where a simple stress analysis was used to help determine the limiting depth for safely mining in bump-prone ground. The second case history is a room-and-pillar retreat mine where the LaModel analysis is used to help optimize the pillar extraction sequencing in order to minimize the frequent pillar line bumps. The third case history is the Crandall Canyon mine where an initial bump and then a massive pillar collapse/bump which killed 6 miners is extensively back-analyzed. In these case histories, the calculation tools in LaModel are ultimately shown to be very effective for analyzing various aspects of the bump problem, and in the conclusions, a number of critical insights into the practical calculation of mine failure and stability developed as a result of this research are presented.