Open Cut Depressurisation

Project Name

Open Cut Depressurisation

Location

Bulga Open Cut Mine

Type

Surface to In Seam (SIS)

Meters Drilled

6,309

Duration

4.5 months

Initial Problem

• The mine required access to a target seam via a new box cut, targeting unmined coal.

• Piezometer data showed hydrostatic pressure (~2300 kPa) and gas content up to 12 m³/t (methane) at  shallow depths.

• High pressure and gas content created safety risks, potentially creating an unsafe explosive loading and mining environment.

Project Objectives

  1. Depressurise the seam for safe,  continuous mining.
  2. Use innovative Surface to In Seam (SIS) bilateral gas drainage wells
  3. Maintain safety and minimise delays; explore gas utilisation and NGERs benefits.

Technical Approach and  Well Infrastructure

• SIS drill pad was set outside the mining area at elevation for safety and access.

• Three build sections (~1500m each, 45° entry) were drilled from the pad, each branching into two  ~500m laterals, providing six lateral wells through the target area.

• Total meters drilled: 6,309m.

• Drilling completed in 4.5 months (18.7 m/hr average drilling rate).

• Lucas Drilling provided full in-house support: well planning, drilling engineering, geosteering, steering, and project management.

• The proposed design of three wells each with a lateral pump provided drainage redundancy to ensure success.

• Detailed engineering (post tender) reduce  project duration by 45% and locked in significant project savings.

Challenges Faced

• Hard, non-porous tuffs and high methane caused major fluid losses and required a switch to  foam drilling.

• Rig operated from an 80m x 40m pit bench.

• Pressurised seam below the water table required balanced, then underbalanced, drilling.

• Water delivery challenges impacted progress.

• Frequent use of lost circulation material (LCM) and aerated fluids was needed.

Key Learnings

• SIS well design and underbalanced drilling enabled safe completion of the laterals.

• A robust risk assessment process and real-time  rig monitoring provide excellent guidance for decision making.

• Lucas Drilling’s integrated project delivery and collaboration with the client, client consultant and site teams ensured success.

• Frequent budget review and cost tracking ensured the project budget was not exceeded

• Adaptability and resilience overcame geological and operational challenges

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