TO 295 .U4 No. 8829 fc° A-^fe-.\ 4 &0 .-^fa-°- *<♦*&;•% ^•afeA >W V.-. V^V V™V V^V V*^*** ^ *'T7T«- A .7" .6^ «"* ;. ^o* •« *y "o, *'7VV* A <>. *'"•.** 9- A'' ^ '^Wff ♦* ^ * *^ *• .f % , • <& 4> V - » o <* .^t. Atffe.- ^.-^fc\ Jti&f> /•*% *+** 5<^ ^<2e. ^*C, ' >* X 'WW >*' *« ^%/^Pv* %/^^v* %;^^v* %/S^v* %/^^v* 6°* > v % .j^ * 0, nK. v ■5°* v^..r V >,•*»&.%. y.^vi,^ ^a&-.%, ^° ^&:^ ^/jsfe-.v .^° ^ J£J 8829 Bureau of Mines Information Circular/1980 Review of Horizontal Drilling Technology for Methane Drainage From U. S. Coalbeds By Gerald L. Finfinger and Joseph Cervik UNITED STATES DEPARTMENT OF THE INTERIOR Information Circular 8829 Review of Horizontal Drilling Technology for Methane Drainage From U. S. Coalbeds By Gerald L. Finfinger and Joseph Cervik UNITED STATES DEPARTMENT OF THE INTERIOR Cecil D. Andrus, Secretary BUREAU OF MINES Lindsay D. Norman, Acting Director This publication has been cataloged as follows: Finfinger, Gerald L Review of horizontal drilling technology for methane drainage from U.S. coalbeds. (Information circular - Bureau of Mines ; 8829) Bibliography: p. 18-19. L Coal mines and mining — United States— Safety measures, 2. Mine gases. 3. Methane. 4. Boring. I. Cervik, Joseph, joint author. II. Title. III. Series: United States. Bureau of Mines. Information circular ; 8829. TN295.U4 622s [622'. 8] 80-13976 ^ CONTENTS Page Abstract 1 Introduction 1 Underground drill equipment 2 Drainage and control technologies 11 Experience with horizontal drilling 14 <^2 Pittsburgh coalbed, Pa. and W. Va 14 Sunnyside coalbed, Utah 15 Beckley coalbed, W. Va 15 Mary Lee and "Blue Creek" coalbeds , Ala 15 Pocahontas No. 3 coalbed, Va 16 Hartshorne coalbed , Okla 16 "B" seam, Colo 16 Summary 16 References 18 Appendix. --Drill units 20 ILLUSTRATIONS 1. Handheld air drill 2 2. Post-mounted electrohydraulic drill 3 3. Longyear horizontal drill 3 4. Longyear power unit 4 5. Lambert drill 4 6. Acker Drill Co. drill 5 7. J. H. Fletcher and Co. drill 6 8. Longyear Drill Co. drill 7 9. Victor drill 8 10. Dresser drill 9 11. Atlas Copco drill 10 12. Spring-loaded ball valve that closes automatically to prevent the flow of methane under unsafe conditions 12 13. Steel pipeline, 3/4-inch PVC pipe, sensor head 13 REVIEW OF HORIZONTAL DRILLING TECHNOLOGY FOR METHANE DRAINAGE FROM U.S. COALBEDS by Gerald L. Finfinger 1 and Joseph Cervik ABSTRACT This Bureau of Mines publication reviews underground methane drainage pro- grams being conducted in various coalbeds. Equipment used in drainage programs such as drills, underground pipelines, and methane monitoring systems is described. INTRODUCTION The Bureau of Mines has been conducting research in mine safety since its inception in 1910. Because uncontrolled release of methane from a coalbed is a serious safety hazard in underground coal mining, the Bureau has conducted an extensive program to study methods of controlling methane emissions. An impor- tant part of this program is the work done to determine the feasibility and effect of methane drainage from coalbeds before mining. Previous work includes studies aimed at understanding the formation and migration of methane in coal- beds (2, 8) 3 and field test methods to remove methane ahead of mining (5-6, 9). One of the most effective methods of degasif ication has been the drilling of small-diameter (3- to 3-1/2-inch) drainage holes horizontally into the coal- bed. Horizontal holes have recently been drilled to lengths more than 2,000 feet by Bureau personnel and others (4, 10, 13). A large part of the Bureau's research effort has been directed toward developing safe and effi- cient techniques for drilling boreholes and conveying the flow of methane to the surface. Experience has shown that underground horizontal boreholes have a great potential for producing large-volume flows of methane. Every foot drilled in the coalbed from underground locations is productive and gas flows increase as hole length increases. In using horizontal boreholes, dewatering pumps are not necessary because gas pressure forces water out of the hole so that methane can be recovered through the use of simple and inexpensive gas-water separators. Geologist. Supervisory Geophysicist. All authors are with the Pittsburgh Research Center, Bureau of Mines, Pittsburgh, Pa. Underlined numbers in parentheses refer to items in the list of references preceding the appendix. UNDERGROUND DRILL EQUIPMENT 4 When the Bureau began its horizontal drilling program, very little information on drilling techniques was avail- able. Early field studies were conducted to determine the proper procedures for drilling short horizontal boreholes (_7) . The first drills used were handheld (fig. 1) or post -mounted and electrohydraulic (fig. 2). These drills are easily transported but are not capa- ble of easily drilling holes to lengths of up to 1,000 feet. Recognizing the poten- tial of long horizontal drainage holes for degasifi- cation of coalbeds, the Bureau studied factors that influenced bit trajectory, developed methods and equip- ment for controlling bit trajectory, and designed, built, and tested a longhole drill unit for drilling horizontal boreholes to at least 1,000 feet. E. J. Longyear Co. 5 designed the Bureau's first electrohydraulic longhole drill equipment (figs. 3-4). The drill unit is equipped with gages to monitor bit rotational speed, torque, and thrust. The thrust potential of the drill unit is 13,000 pounds at 2,000 psi hydraulic pressure. Feed length is about 11 feet and the overall length of the drill unit is about 18 feet. The power unit (fig. 4) consists of a 30-hp, 440 vac motor that drives hydraulic pumps to operate the thrust and spindle rotation motors on the drill unit. Using the Longyear drill, horizontal boreholes have been drilled to lengths of 2,110 feet without reaching the capacity of the drill unit (4). One disadvantage of the Longyear drill (fig. 3) is its 18-foot length, which makes it difficult to maneuver in underground locations. The drill could be shortened to facilitate underground handling, but then the 11-foot feed would be sacrificed. An electrohydraulic longhole drill that is much ^This report includes discussion of drills developed for horizontal drilling underground. Comprehensive coverage of all drills that may be used for such purpose is not intended. 5 Reference to specific equipment, trade names, or manufacturers does not imply endorsement by the Bureau of Mines. FIGURE 1. - Handheld air drill, FIGURE 2. - Post-mounted electrohydraulic drill. ry*r rp Scale, feet FIGURE 3. - Longyear horizontal drill. smaller and more compact than the Longyear drill (fig. 5) was designed by the Bureau and constructed by Lambert Drilling Co. Although the feed length is limited to 2 feet, the Bureau's experience indicates that bit control during drilling is not affected by frequent interruptions in drilling because of the short feed length. A particular disadvantage of the Lambert drill is the slow retraction after the spindle has been extended its maximum length. Some hori- zontal boreholes have been drilled to 2,500 feet with no indications that the drill had reached its capacity (10). Bit thrust potential of the drill is 34,000 pounds at 2,000 psi hydraulic pressure. The drill is equipped with FIGURE 4. - Longyear power unit. FIGURE 5. - Lambert drill. gages to monitor bit thrust, torque, and rotational speed. Setting a drilling angle is a simple adjustment because the drill head swivels through 360°. This type of drill is presently marketed by Sprague and Henwood Co. , Scranton, Pa. Both the Longyear and Lambert drills are cribbed during drilling to the proper height and angle so that the horizontal borehole is started in about the center of the coalbed and parallel to the bedding planes. In addition, the drills are anchored to the coalbed to prevent backward movement of the drill when high thrusts are being applied to the bit. At the start of drilling, a 6-inch-diameter hole is drilled to a depth of about 22 feet and a 4-inch casing is then cemented in the hole. A gas-water separator that provides the means for controlling methane during drilling is attached to the steel casing. Much of the labor involved in cribbing and angling drills underground becomes unnecessary with the drill equipment designed by Acker Drill Co. , Inc. , and J. H. Fletcher and Co. (figs. 6-7) , which are similar to the drill designed by Longyear. The feed frames of the Acker and Fletcher drills can be hydrau- lically elevated above floor level and angled above or below the horizontal plane automatically. Gas-water separators are also an integral part of the drills. The drill carrier for the Acker and Fletcher drills are four-wheeled vehicles and are hydraulically powered so that the equipment can be trammed. All of the preceding drills have power units that can be separated from the drill units by as much as 500 feet. The only connections between the drill and power units are hydraulic hoses except for the Acker and Fletcher drills which have Mine Safety and Health Administration (MSHA) permissible illumina- tion. The hydraulic fluid is circulated by an electrically driven hydraulic FIGURE 6. - Acker Drill Co. drill. FIGURE 7. - J. H. Fletcher and Co. drill. pump from the reservoir on the power unit to the drill unit. Therefore, the drills can be used in return airways while the power unit remains in fresh air. The Acker, Fletcher, and Lambert drills are equipped with hydraulic chucks that greatly reduce the time of chucking and pipe pulling operations. Longyear, Inc. , designed a second electrohydraulic drill with the drill and permissible power unit mounted on the same frame (fig. 8). Because the drill unit cannot be separated from the power unit, its use is limited to intake air and face areas except in States where permissible equipment can be operated in return airways. The drill is a smaller version of the first drill Longyear designed (fig. 3); feed length is only 6 feet compared with the 11-foot length of the first drill. The drill is equipped with a hydraulic chuck and gages to monitor bit thrust, torque, and rotational speed. FIGURE 8. - Longyear Drill Co. drill, Other drills that can be used to drill horizontal boreholes are manufac- tured in Europe and marketed in the United States. These drills are electro- hydraulic, smaller and lighter than the preceding five drills, and generally are mounted on posts. In Europe, these drills are used to drill methane drainage holes into strata above the mined coalbed. The Victor Minotaur drill (fig. 9) marketed by Dowty Corp., Pittsburgh, Pa., the Boyles Bros. Model HNH drill (fig. 10) marketed by Dresser Industries, Inc., Dallas, Tex., and the Atlas Copco Diamec 250 drill (fig. 11) marketed by Christensen Diamond Products, Salt Lake City, Utah, are similar in construction. Each has a drill head that is mounted on a feed frame. The feed length ranges from 2.5 feet for the Victor drill to 5 feet for the Atlas Copco and to 7 feet for the Boyles 1 drill. The Atlas Copco drill will probably require modification before it can be used routinely for drilling in coalbeds because the thrust and rotation cannot be controlled independently; such control is essential for change in bit inclination. For ease in underground maneuvering, each of these drills can be fitted with axles and wheels. o o > LU O O LLI a: Z> o 10 o u Q. O u w a Z> o 11 Horizontal drilling technology has been developed by the Bureau to the point where lengths of 1,000 feet are easily attained (12). In some cases, holes have been drilled to 2,100 feet, but with difficulty (4). Surveying to determine bit angle is an important part of horizontal drilling. Bore- holes should be surveyed at least every 20 feet to determine bit inclination. If the bit begins to deviate from its programmed trajectory, bit thrust and rotational speed must be changed to keep the bit within the coalbed. Bit inclination can be determined using commercially available pumpdown equipment such as the single-shot instruments by Sperry Sun and Eastman Well Surveying Co. An in-hole cableless surveying unit is being developed by Ensco under contract with the Bureau. DRAINAGE AND CONTROL TECHNOLOGIES Drainage of the large volumes of methane produced from horizontal holes requires underground pipelines to transport methane to the surface. Under- ground methane pipelines for gob gas have been used by the coal mining industry in Germany since 1943 (1). After World War II, increased production due to mechanization, and mining of deeper and gassier coalbeds, necessitated methane drainage throughout European coalfields, where it now is a fully integrated part of longwall mining (3) . Most underground methane pipelines in the United States are experimental and use both steel and plastic lines. Because of the risk of damage from roof falls and bottom heaving, it is important to include a means of shutting off the flow of methane from the drainage hole to prevent methane from escaping from a damaged or faulty pipeline. Automatic shut-in of each horizontal hole is accomplished by means of a spring-loaded ball valve (normally closed) that is held open with 55 psig of compressed air (fig. 12) supplied by a small compressor (1 cfm, 50 psig). Compressed air is piped to the pneumatic valve for each hole through brittle polyvinyl chloride (PVC) pipe strapped to the top of the pipeline along its entire length (fig. 13). Methane sensing and control systems, which are commercially available, vent the compressed air line and consequently close the pneumatic valves should abnormal methane con- centrations be detected. The pneumatic valves close automatically when a sensor malfunctions, when an electrical line to a sensor is cut or broken, or when the PVC pipe is broken by a roof fall. Requirements for underground methane pipelines will vary depending upon the type of pipe, the location of the pipeline, and the amount of methane gas transported. Guidelines for installation, maintenance, and safe operation of underground pipelines have been developed by the Bureau (16) and MSHA (15). 12 o o ■♦— o E o o V) 0) to o o « (/) D © > -t- — ~a -° 8 ■ D c - .E o 4 .0 * a> ... V* a aV ** w lV- • • * A * VV-IK-" S\ ' <>. * • . o ° 4 «F V^V ..... v o* 6 — \ *° »!i»ftC*. ^ „V % .•«••-. ^ a9*.«^ *> *^o* ^°- °o. '»(■>' \