- Conference Article
- 10.2118/229179-ms
Advancing Geothermal Well Engineering Through Cutting-Edge Drilling and Workover Designs
- Nov 03, 2025
- J J R Cayao + 1 more +1
The distinct characteristics of geothermal wells necessitate a unique and specialized approach to well design. This is critical for prolonging well lifespan and tackling the unique operational challenges present in mature geothermal fields, such as the case on a field in the Philippines. To enhance steam production, geothermal wells often intersect faults and complex geological formations, which result to partial to total fluid losses. These losses introduce significant uncertainty in cementing and compromise its quality. Such issues can lead to channeling, the formation of micro-annuli, and cement degradation — all of which undermine well integrity and reduce production efficiency. Furthermore, these cementing challenges, especially in the case of geothermal wells, may result to having trapped fluid in casing-to-casing annulus that can potentially compromise well integrity due to huge temperature swings that the wells encounter over their operating lives. Addressing these integrity concerns in a cost-effective manner is critical to maintaining safe, efficient, and economically viable well operations over time. To overcome these challenges, Welltec partnered with a geothermal operator in the Philippines to rehabilitate eight geothermal production wells affected by casing collapse and parted casing. A traditional workover involving bridge plugs was deemed impractical, as drilling out the plug risked further damage to liners exposed to corrosive, low-pH fluids. There was also a concern that trapped fluids could trigger additional casing failures. Therefore, a more controlled and precise cementing strategy was required to restore casing integrity. This paper introduces a tailored solution that integrates high-temperature Metal Expandable Packer technology and stage cementing collars. Case studies from a geothermal field in the Philippines illustrate how this approach restores well integrity without the need for a dedicated drill-out run. Building on experience from prior deployments, the improved MEP enables long-string tieback and casing relining to depths of approximately 1,300 meters — previously considered unattainable due to casing collapse, which had limited operations to around 700 meters. New well designs using CRA are also being optimized to benefit from such solution and withstand highly acidic environments. These wells require immediate relining, applying insights from earlier CRA wells in the same field. The MEP system eliminates the need to drill out plugs, thereby preventing damage to CRA casing. Integrating MEP technology into both drilling and workover operations offers a robust strategy to resolve integrity issues that typically lead to early well failure. This geothermal-specific technology enhances repeatability, safety, and operational control, ultimately enabling more reliable and extended utilization of geothermal resources.
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