WellDynamics

WellDynamics
Halliburton WellDynamics is the world's leading provider
of intelligent completion technology to the upstream oil
industry. Introduced in 1997, the WellDynamics
SmartWell® system technology was the industry's first
intelligent well completion system and was designed
specifically to remotely control and monitor specific
reservoir zones without intervention.
Today, Halliburton WellDynamics offers a broad
complement of products and services that range from
reservoir engineering studies to advanced completion design,
zonal isolation and flow control, reservoir monitoring, and
surface digital infrastructure solutions.
SmartWell systems are designed to meet the demands of
every intelligent completion in all global areas and
environments. Halliburton WellDynamics has designed its
product lines and solutions accordingly.
• Flow control solutions include interval control valves
(ICV), lubricator valves (LV), packers, and downhole
control systems.
• Permanent monitoring solutions include downhole
gauges and flowmeters.
• Digital infrastructure solutions include a supervisory
control and systems designed for manual, automatic, and
integrated operation and electro-hydraulic control and
monitoring systems.

SmartWell® Systems • Optical fiber solutions include distributed temperature

sensing (DTS) tools and software.

A SmartWell completion system optimizes production by Reliability

collecting, transmitting, and analyzing completion,
production, and reservoir data; allowing remote selective Reliability is essential for intelligent completion systems, and
zonal control and ultimately maximizing reservoir Halliburton WellDynamics engineers reliability into all of its
efficiency by: equipment. The company is ISO 9001 application certified
and has developed processes to guide, monitor, and optimize
• Helping increase production – Commingling of
system delivery and performance. In addition, Halliburton
production from different reservoir zones increases and
WellDynamics has a dedicated Reliability Assurance
accelerates production and shortens field life.
department that manages reliability tools and processes.
• Helping increase ultimate recovery – Selective zonal
control enables effective management of water injection, Halliburton WellDynamics maintains a detailed database to
gas and water breakthrough, and individual zone track the field performance of each SmartWell system
productivity. installation. The knowledge gleaned from this data is used to
• Helping reduce capital expenditure – The ability to calibrate design predictions and optimize the design and
produce from multiple reservoirs through a single production process.
wellbore reduces the number of wells required for field
development, thereby lowering drilling and completion
costs. Size and complexity of surface handling facilities
are reduced by managing water through remote
zonal control.
• Helping reduce operating expenditure – Remote
configuration of wells optimizes production without
costly well intervention. In addition, commingling of
production from different reservoir zones shortens field
life, thereby reducing operating expenditures.

WellDynamics 3-1
Flow Control Valves
Halliburton WellDynamics offers interval control valves
(ICV) both with and without shrouds and deflectors:
• HS-ICV – Interval control valve for deepwater and high-
pressure/high-temperature applications
• IV-ICV – Interval control valve at the core of Halliburton
WellDynamics' SCRAMS® surface controlled reservoir
analysis and management system
• MCC-ICV – Cost-effective valve with choking capability
• LV-ICV – Lubricator valve
HS-ICV Valve
Halliburton WellDynamics' HS interval control valve is the
next-generation downhole control valve designed for
Halliburton WellDynamics' industry-leading SmartWell®
intelligent completion systems. The HS-ICV is designed for
deepwater and high-pressure/high-temperature applications
in which operating conditions are extremely severe.
The HS-ICV's eight-position standard gas/liquid flow trims
have been characterized to provide optimum production/
injection at various positions. Optional onboard sensors
track the movement of the flow trim. These position sensors
provide the operator with real-time feedback to confirm
valve movements.
HAL30642
3-2
Features
• Proprietary, debris-tolerant, metal-to-metal seal
• Customizable gas/liquid flow trim
• Can be used in simple on/off intervention avoidance
applications or in more versatile advanced reservoir
management choking applications with the
Accu-Pulse™ module
Benefits
• Remotely control flow into or out of the reservoir in
challenging environments such as deepwater and HPHT
• Eliminate the potential for wellbore debris to be trapped
inside the tool and consequently prevent valve
movement or impact sealing integrity
• Obtain real-time confirmation of remotely actuated
valve movements using optional position sensors
• Unload at a maximum differential pressure of 5,000 psi
without the threat of any valve damage—the highest
unloading capacity in the industry
WellDynamics
Operation
Hydraulically actuated, the HS-ICV is operated remotely
from surface using Halliburton WellDynamics' reliable Direct
Hydraulics, Digital Hydraulics™, or SmartPlex™ downhole
control system. The premium thermoplastic hydraulic
chamber seals are designed to operate under high actuation
pressures and over temperatures ranging from 40°F (4°C) to
330°F (165°C). The valve has also been subjected to a
stringent qualification program, including temperature,
pressure, debris, and erosion tests.
The HS-ICV body has slots to accommodate two 1/4-in.
dedicated instrument wires for position sensors and allows
bypass of up to six 1/4-in. bare hydraulic control lines or
instrument wires—all without compromising valve body
rating or working envelope.
Debris-Tolerant Design
The HS-ICV has been designed and tested such that the flow
trim will ensure complete metal-to-metal (MTM) seal
integrity even when exposed to heavy wellbore debris. A one-
piece valve mandrel design eliminates the potential for
wellbore debris to be trapped inside the tool and
consequently prevent valve movement.
Proprietary MTM Seal
The HS-ICV houses a proprietary metal-to-metal flank seal
that enables the valve to unload at a maximum differential
pressure of 5,000 psi without the threat of any valve
damage. Any additional tubing or annulus pressure acts on
the MTM seal to further ensure seal integrity, which has
been rigorously tested and qualified at low- and high-
pressure (up to 10,000 psi) differentials.
Simple On/Off or Choking Applications
The HS-ICV is designed for simple on/off applications or
more versatile choking applications if used in conjunction
with the Accu-Pulse™ incremental positioning module.
For the choking application, the HS-ICV comes fitted with a
standard liquid or gas flow trim, depending on the well
application. These trims can also be customized to suit a
particular well's injection or production philosophy.
Tungsten carbide is the material of choice for these flow trims
to combat the threat of erosion due to high flow rates.
Position Sensor
The HS-ICVs can be fitted with onboard position sensors
which track the movement of the flow trim. These sensors
provide the operator with real-time feedback to confirm
remotely actuated valve commands.
In dry-tree choking applications, the position sensor feedback
can be used in conjunction with Halliburton WellDynamics'
surface positioning technology to remotely position the ICV,
eliminating the downhole Accu-Pulse module requirement.
Shrouded Versions
A shrouded configuration of the HS-ICV is available
primarily for a two-zone stacked gravel pack application. The
shrouds can also be shrink-fitted with a carbide insert when
the valve is used in a stacked gravel pack injection application.

Pressure-Balanced Valve Mandrel

A pressure-balanced valve mandrel design eliminates the need
for a latch mechanism to hold the trim closed or the need to
maintain hydraulic pressure on the close chamber to keep the
flow trim shut. This balanced sleeve design also prevents
drifting of the sleeve in the incrementally open position.

The valve mandrel design also includes a shifting profile that

allows the sleeve to be mechanically shifted in the event that
hydraulic control has been compromised or if sleeve
momentum is not achievable due to scale buildup inside
the ICV.

WellDynamics 3-3
IV-ICV Valve
Halliburton WellDynamics' infinitely
variable interval control valve (IV-ICV)
is a remotely operated control valve that
controls flow into or out of an isolated
reservoir interval. The IV-ICV is used
where selective control over production
or injection is required. The IV-ICV
allows the operator to alter the flow
characteristics of the zone without
mechanical intervention. It is run in
conjunction with the SCRAMS® surface
controlled reservoir analysis and
management system.
Features
• Infinitely variable choke positioning
• Seal locking mechanism that
eliminates the requirement for
hydraulic pressure to be maintained
• Incremental choke control can be
achieved electro-hydraulically
or hydraulically
• Mechanical override facility
• High integrity metal-to-metal
(MTM) choke sealing
• Shrouded version available for
stacked zone applications
• Flow area equivalent to tubing
flow area
Benefits
• Control of reservoir intervals
without the requirement for
well intervention
• Ability to alter flow characteristics
of each zone
• Flow allocation capability through
SAM™ sensor actuation module tool
Operation
The IV-ICV is controlled by differential
pressure applied to the actuator piston.
A minimum of 250 psi differential is
needed to unlock the MTM seal and
allow the choke to open. The choke can
then be positioned incrementally
between fully closed and fully opened.
3-4
Seals
The primary IV-ICV seal mechanism is
a metal-to-metal spring-loaded
apparatus, which provides high
integrity sealing. The IV-ICV holds the
MTM seal with a locking mechanism,
eliminating the need for hydraulic line
pressure to be maintained. The unique
configuration of the seal mechanism
provides increased preload to the MTM
seal ensuring a tighter seal at higher
differential pressures. The MTM sealing
mechanism is capable of handling
7,500 psi differential in the closed
position and 5,000 psi differential
during opening.
The choke mechanism incorporates a
tungsten carbide element which has
been field-proven in extremely corrosive
conditions and has undergone extensive
accelerated life testing to establish its
limits in a wide variety of flow
conditions. The flow wetted seal stacks
consist of PTFE- and PEEK™ seal-based
thermoplastic elements, which have
been extensively tested in oil, water, and
nitrogen to demonstrate thermal and
pressure cyclic performance. The system
has the ability to tolerate multiple shifts
at the rated shifting pressure
differential.
Qualification Testing
The IV-ICV has been successfully
subjected to rigorous qualification
testing. A brief summary of the tests
carried out are as follows:
• Cv determination for complete tool
HAL33639
• Cv determination for commingled
flow
• Qualitative and quantitative erosion
IV-ICV
testing Valve
• Quantitative vibration testing
• Short-term erosion evaluation at
high flow rates (86,000 B/D) to PEEK is a trademark of ICI Americas, Inc. Poly-
Ether-Ether-Ketone.
simulate stimulation effects;
qualified to 57,000 B/D for short-
term high flow rate applications
WellDynamics
MCC-ICV Valve
The MCC-ICV is a multi-position valve that provides
incremental flow control over individual reservoir zones,
allowing optimization of reservoir architecture down hole
and maximizing recovery.

The Halliburton WellDynamics surface control systems

provide accurate incremental control over the MC-ICV choke
trim and can be tailored to fit the operator's needs.

The MCC-ICV is fitted with a tungsten carbide flow trim to

control erosion from aggressive downhole conditions.

The valve is available in a range of sizes and thread

configurations and can be coupled with either an automatic
or manual control system to accommodate specific
operational requirements.

Nominal Well Conditions

MC-ICVs have been specifically designed for use in wells
with the following normal conditions:
• 5,000 psi maximum differential pressure
• Negligible H2S and CO2
• BHT < 275°F
• Moderate duty cycle (open/close with pressure
differential)

Features
• Simple cost-effective design
• Bonded nitrile seals
• Open/close functionality in the MC0-ICV
• Multi-position functionality with tungsten carbide flow
trim in the MCC-ICV
HAL33642

• Manual override

Benefits
MCC-ICV
• Cost-effective SmartWell® system functionality in Valve
moderate service conditions
• Remote control of reservoir intervals without the need
for well intervention

WellDynamics 3-5
 Interval Control Valves

Maximum Differential Unloading Pressure psi

Maximum Temperature Rating Available °F
Maximum Working Pressure Available psi

Flow Area, OD of HS - ID of Deflector in.²

Maximum Hydraulic Chamber Rating psi

Hydraulic Chamber Displacement in.³

Flow Area, ID of Shroud-ICV OD in.²

Minimum Internal Flow Area in.²
Maximum OD Available in.

Deflector OD Available in.

Minimum ID Available in.

Shroud OD Available in.

Shroud Size/Weight

Deflector Available
Version Available
Piston Area in.²

Total Stroke in.

Availability
Size in.
Type

7,500 6.00 10.29 Choke Yes 5 1/2 in.

2 7/8 10,000 275** 4.660 2.313 2.20 1.716 5,000 5.800 5.030 No N/A N/A
10,000* 3.28 5.62 On/Off TBA 20 lb

7,500 6.00 11.94 Choke Yes

10,000 7 in.
3 1/2 10,000 330 5.850 2.750 4.62 1.990 5,000 7.070 7.980 Yes 7.685 6.38
3.28 6.53 On/Off Yes 29 lb
HS Series

15,000* 17,500

7,500 6.00 16.68 Choke Yes

10,000 3.750 7 5/8 in.
4 1/2 10,000 275** 7.125 11.04 2.780 5,000 8.535 9.300 Yes 8.315 5.17
3.28 9.11 On/Off Yes 39 lb
15,000* 17,500 3.560

7,500* 6.00 25.44 Choke TBA

5 1/2 10,000 275** 8.279 4.562 16.38 4.240 5,000 No N/A N/A Yes 9.330 N/A
10,000* 3.28 13.90 On/Off TBA

2 7/8 5,000 5,000 275 4.660 2.250 3.98 1.870 6.00 11.22 Choke Yes 1,000 Yes 5.500 3.800 No N/A N/A
MC Series

3 1/2 5,000 5,000 275 5.468 2.750 5.94 2.558 6.00 11.87 Choke Yes 1,000 No N/A N/A No N/A N/A

Notes:
Special ID valves are made to order.
OD of valves will be bigger if a 3/8-in. bypass is required for chemical injection.
Chemraz® seals are standard on HS-series valves (70°F to 330°F). Cold array seal stacks (40°F to 275°F) are under development.
HS-series valves are available in various metallurgy to suit well conditions.
HS-series provides incremental positioning only in conjunction with an Accu-Pulse™ control module.
HS-series choke trims can be customized to suit clients needs.
HS-series 2 7/8-in. size choking valve is eccentric in design.
MC-series valve is available as a standard where metallurgy, thread connections, flow trims, seals etc.
The HVC and IV-series ICV is being phased out. Contact Halliburton for information on these products.
*Pending qualification testing
**Ultimate goal is to get the temperature rating of the HS product line to 330°F.
Please contact Halliburton for more details.
Chemraz is a registered trademark of Greene, Tweed & Co., Inc.

3-6 WellDynamics
LV-ICV Lubricator Valve
Halliburton WellDynamics' lubricator valve (LV) is a high- The LV-ICV is available in different sizes and materials to suit
performance, remotely controlled, tubing-conveyed specific well configurations.
downhole lubricator system. The LV isolates pressure or flow
above or below its position in the tubing string.

The LV can be used in any completion where pressure or flow

isolation in the tubing string is required.

When included in a SmartWell® intelligent completion

system, the LV can be used to control flow into or out of
reservoir intervals. The LV can be controlled by any of
Halliburton WellDynamics’ Direct Hydraulics, Digital
Hydraulics™ systems, or SCRAMS® control systems.

The LV incorporates a ball with full open bore ID. Two

control lines are connected to the LV, one at each side of the
operating piston. Pressure applied to one control line opens
the LV, allowing pressure or flow to pass through the ball.
Pressure applied to the other control line closes the LV on the
valve sealing surface for pressure integrity.

Because the ball seals on the same surface for flow/pressure

from above and below, the LV-ICV pressure integrity is fully
testable from surface.

Features
• Full bore ID
• Deep set capability
• Minimal moving parts
• High force actuation for both open and close operations
HAL33641

Benefits
• Helps ensure pressure integrity from above and below
• Helps control reservoir intervals without the LV-ICV Lubricator
requirement for well intervention Valve

LV-ICV Valves
Maximum Maximum
Maximum Maximum Hydraulic Unloading Hydraulic
Maximum Pressure Pressure Chamber Differential Piston Total Chamber Internal
OD ID Temperature (Ball Open) (Ball Closed) Pressure Pressure Area Stroke Displacement Flow
Size in. in. °F psi psi psi psi in.² in. in.³ Area in.²
3 1/2 5.705 2.890 280 7,500 5,000 7,500 1,000 3.360 2.100 7.050 6.560
4 1/2 7.155 3.813 280 7,500 5,000 7,500 1,000 3.980 2.510 10.000 11.420
5 1/2 8.015 4.620 280 7,500 5,000 7,500 1,000 4.670 3.080 14.400 16.800
Notes:
Valve OD will increase if a control-line bypass is required.
Valve is available in various metallurgy.
Valves use Chemraz®, PEEK®, and Viton® seals.
Please contact Halliburton WellDynamics for additional information.
Chemraz is a registered trademark of Greene Tweed & Co., Inc. PEEK is a trademark of ICI Americas, Inc. Poly-Ether-Ether-Ketone. Viton is a registered
trademark of DuPont Dow Elastomers, LLC-Fluorocarbon.

WellDynamics 3-7
sSteam™ Valve
Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity
Drainage (SAGD) are widely used enhanced oil recovery
(EOR) methods for extracting bitumen or hydrocarbons in
heavy oil reservoirs. To help optimize production in CSS and
SAGD applications, Halliburton WellDynamics has
Splice Protection
developed the sSteam™ valve. The sSteam valve allows
Sleeve
uniform or selective steam placement along the entire length
of the horizontal section of the wellbore.

This robust downhole technology is designed to handle high

temperatures (500°F) and moderate pressures associated
with steam injection. The sSteam valve can be deployed as
part of the production liner with or without zonal isolations.

Features Open Line

• 500°F temperature rating
• 3,000 psi working pressure
• High-temperature control-line fluid
• Metal-to-metal closure seal
• Remotely operated

Benefits Metal-to-Metal
• Permits uniform or selective placement of steam across Closure Seal
the wellbore
• Places uniform steam chamber under variant reservoir Tubing
and steam quality conditions Equivalent
Flow Area
• Prevents steam breakthrough by selectively shutting off Ports
a valve

Common
Close Line
Common
Close Line
HAL31791

sSteam™ Valve

3-8 WellDynamics
Operation
Halliburton WellDynamics’ reliable Direct Hydraulics This hydraulic control fluid retains its desired viscosity
downhole control system uses hydraulic lines connected when subjected to the extreme temperatures of the CSS /
directly from the surface to remotely actuate the sSteam™ SAGD environment.
valve. Each of the two control lines required to operate the
valve is connected to the open or close side of the valve In the event of steam breakthrough, the sSteam valve can be
respectively. If multiple valves are present, the close side is selectively shut off, thus allowing efficient hydrocarbon
networked to a common close line, and the open side of each recovery without the threat of injected steam being produced
valve has a dedicated open line. A specially developed or the need to shut down production to cool the reservoir.
hydraulic control fluid is used to operate the valve.
sSteam™ Valve
Tubing Size
3.5
in.

Maximum OD
5.430
in.

Minimum ID
2.735
in.

Length
53.5
in.

Top and Bottom Connection 3.5-in. 8 rd 9.3-lb EUE Box × Box

Service Steam

Maximum Working Temperature

500
°F

Working Pressure (Internal and External)

3,000
psi

Test Pressure (Internal and External)

3,000
psi

Base Metallurgy A005 (4140)

Fastener Metallurgy Stainless Steel

Piston Area
5.15
in.²

Total Stroke Open-Close

4.419
in.

Tensile Rating*
207,000
lbf

Compressive Rating*
207,000
lbf

Minimum Internal Flow Area

5.87
in.²

Control-Line Bypass 6 × .25-in. lines

Variations 2 Position / Open-Close

*Based on 9.3-lb tubing

WellDynamics 3-9
sFrac™ Valve
Halliburton WellDynamics' sFrac™ valve is a remotely
operated, downhole hydraulic valve that offers cost-effective
multi-stage fracturing capabilities to operators working in
areas with tight gas or difficult-to-produce reserves. Available
in 3 1/2-in., 4 1/2-in., and 5 1/2-in. sizes, the sFrac valve can
be installed with Swellpacker® isolation systems or cemented
in place with the casing string. Later in the life of the well, the
sFrac valve can be used for re-stimulation or selective shutoff
of unwanted water or gas.

Features
• 10,000 psi rating
• Remotely operated
• Can be operated after being cemented in place
• Large ports to reduce erosion
• Large piston areas for debris tolerance
• Available in 3 1/2-in., 4 1/2-in., and 5 1/2-in. sizes

Benefits
• Saves rig time and operational expense by selectively
controlling high-rate stimulation in a single well without
mechanical intervention
• Provides a full bore from the upper zone to the
lower zone
• Does not require ball seats to be milled up after
stimulation
• Allows the zones to be fractured in any order
• Allows shut off of water production later in the life of
the well
• Allows re-stimulation with minimal workover
• Gives more contingency options for screenout during
frac operations

The sFrac valve enables operators to economically complete

multiple intervals in a horizontal wellbore in low
permeability sandstones, carbonates, gas shale, and coalbeds.
It allows selective, high-rate, and precise placement of
hydraulic fractures in a multi-zone well without the need for
mechanical intervention.

The sFrac valve can be casing-conveyed and cemented in

HAL32387

place or deployed via production tubing. Feed-through

mechanical packers or Swellpacker isolation systems are used
to isolate cased or openhole intervals as required. sFrac™
Valve

3-10 WellDynamics
 Operation
Halliburton WellDynamics' reliable Direct Hydraulics
downhole control system uses hydraulic lines connected
directly from the surface to remotely actuate the sFrac™
valve. Each of the two control lines required to operate the
valve is connected to the open or close control port of the
valve. If multiple valves are present, each valve's open port is
networked to a common close line and the open port is
connected to a dedicated open line.
When there are enough sFrac valves to make the number of
lines in a Direct Hydraulics system prohibitive, the
SmartPlex™ downhole control system can be used. The
SmartPlex system is a simple, multi-drop, electro-hydraulic
control system that uses two hydraulic lines and one
electrical control line connected directly from the surface to
actuate multiple sFrac valves in a single wellbore. It uses a
passive multiplexing switching method to control each valve
independently even though they are connected to the same
control lines.
Once stimulation has been completed, the sFrac valve
operates as a production device, allowing full wellbore access.
Zones can also be selectively shut off in case of water
breakthrough during the later life of the well. In addition, the
sFrac valve allows re-stimulation at a later date after
production declines.

sFrac™ Valve
Internal and
Maximum Maximum Minimum Maximum
Tubing Maximum Minimum External Piston Tensile Compressive Port Flow
Length Working Hydraulic Internal Unloading
Size OD ID Working Area Rating Rating Area
in. Temperature Pressure Flow Area Differential
in. in. in. Pressure in.² klb klb in.²
°F psi in.² psi
psi

3 1/2 5.430 2.750 85 285 10,000 10,000 5.18 207 207 5.94 8.64 1,500
4 1/2 6.250 3.688 81 285 10,000 10,000 5.73 288 288 10.67 16.57 1,500
5 1/2 8.000 4.650 81 285 10,000 10,000 8.38 530 318 16.97 21.57 1,500
A002 (4140) metallurgy. Can be designed to meet NACE standards with reduced pressure and load ratings.
Bypass for 8 × 1/4 in.
Stainless steel fastener metallurgy

WellDynamics 3-11
Zonal Isolation Packers
HF-1 Packer
Halliburton WellDynamics' HF-1
packer is a single-string, retrievable,
cased-hole packer that features a facility
for bypass of multiple electrical and/or
hydraulic control lines. Available for use
as both the top production packer or as
one of many lower packers isolating
adjacent zones, the HF-1 packer
includes a specialized slip configuration
and additional body lock ring, which
allow it to operate under higher loads
and greater pressures than standard
production packers.
Features
• Hydraulically activated interlock
mechanism prevents premature
setting
• No body movement during setting
• Premium thread connections
• NBR and HNBR element with anti-
extrusion system
• Tailpipe can be left in tension or
compression
Benefits
• Less damage to casing using a multi-
cone, full coverage slip system
• Fully retrievable after installation
• Can be deployed with Halliburton
WellDynamics SmartWell® system
• May be used as both top production
packer and lower isolation packer
• Avoid damage to control line during
setting
Setting Mechanisms
The HF-1 packer has two setting and
three release mechanisms.
• Setting Mechanisms
- Tubing pressure set
- Control-line set
3-12
• Release Mechanisms Integral Element Anti-Extrusion
- Punch and pressure release System
The packing element is multi-piece with
- Shift and pressure release
NBR sealing elements. It incorporates
- Mechanical shift release an anti-extrusion system that provides
The release mechanism is recessed and high resistance to swab off, which
selective, allowing for passage of other permits increased running speeds and
toolstrings. Axial loads are supported in high annular circulation rates (up to
both directions so the tool cannot be 8 bbl/min) prior to setting. The system
released by tubing forces. has been qualified through multiple
thermal cycles using both water and
Connections nitrogen as test media.
The HF-1 packer is made up directly to
the tubing string via integral premium Load and Functional Performance
thread connections. The internal All HF-series packers are ISO-14310 V0
mandrel also uses premium thread or V3 rated.
connections for continuity.
• Anti-pre-set mechanisms – The
HF-1 packer incorporates a
hydraulically activated interlock
system and can be adjusted prior to
running in the hole. The interlock
system allows the packer to be run
in highly deviated or horizontal
wells, eliminating the risk of pre-
setting due to casing drag.
• Tandem setting – The packer is
designed for tandem setting with
tailpipe in tension, compression, or
neutral. The setting mechanism is
independent of tubing movement
or pressure induced tubing forces.
Setting action will not impart loads
on or damage any penetrations or
lines.
Penetrations
Provision is made for the passage of
multiple hydraulic and/or electrical
control lines. All connections are sealed
using Halliburton WellDynamics'
proprietary FMJ connectors.
HAL33644
Elastomeric Seals
Material for setting chamber seals and
tubing to lower annulus is chosen based HF-1
on application conditions. Packer
WellDynamics
 Retrievable Feed-Through HF Packers

Maximum
Differential Required
Casing Casing Mandrel Maximum Bore Maximum Across Working Working Setting ISO
OD Weight Size OD ID Feed- Element Pressure Temperature Pressure Element 14310
Type in. lb/ft in. in. in. Through psi psi °F psi Type Rating

2 7/8 2.315 5,000 5,000

23 6.180 Nitrile V3
3 1/2 2.750 7,500 7,500
26 3 1/2 6.090 2.750 7,500 7,500 4,500 for Nitrile V3
Tubing Set
Nitrile
7 2 7/8 2.315 5 75-275 6,500 for V3
HNBR
Control-
29 5.995 7,500 7,500
2.315 Line Set Nitrile V0
3 1/2
2.750 HNBR V3

32 3 1/2 5.905 2.750 7,500 7,500 Nitrile V3

33.7 6.570 7,500 7,500 4,500 for Nitrile V3
Tubing Set
7 5/8 3 1/2 2.750 5 75-275 6,500 for
39 6.430 10,000 10,000 Control- Nitrile V0
Line Set
4 1/2 3.812
43.5 8.515 7,500 7,500 75-275 Nitrile V3
5 1/2 4.562
7,500 Nitrile
3 1/2 2.750 7,500 75-275 V3
10,000 HNBR
HF1 Series 3.525
(722HF1)
47 8.440 3.788 (a) 7,500 7,500 75-275 Nitrile V0
Production / 4 1/2
(b) 10,000 10,000 40-300 4,500 for HNBR V3
Isolation 3.813
Tubing Set
9 5/8 3.954 6 6,500 for
Control-
5 1/2 4.560 7,500 7,500 75-275 Nitrile V0
Line Set
3 1/2 2.750 7,500 7,500 75-275 Nitrile V0
(a) 7,500 7,500 75-275 Nitrile V0
4 1/2 3.525
53.5 8.300 (b) 10,000 10,000 40-275 HNBR V3
4.560 75-275 Nitrile V0
5 1/2 7,500 7,500
4.625 40-275 HNBR V3

71.8 4 1/2 7.890 3.525 7,500 7,500 75-275 Nitrile V0

60.7 5 1/2 9.430 4.562 6,000 6,000 75-275 4,500 for Nitrile V0
Tubing Set
10 3/4 6 (a) 7,500 7,500 6,500 for Nitrile V0
65.7 5 1/2 9.330 4.562 40-275 Control-
(b) 5,000 5,000 HNBR V3
Line Set
4,500 for
Tubing Set
11 7/8 71.8 4 1/2 10.550 3.688 5 5,000 5,000 75-275 6,500 for Nitrile V3
Control-
Line Set

9 5/8 53.5* 5 1/2 8.300 4.562 5 10,000 10,000 100-350 6,500 Aflas® V0
HFP Series
(722HFP)
62.8 4 1/2 8.440 3.788 10,000 10,000 100-220 V3
Production /
Isolation 9 7/8 5 6,500 Aflas
68** 4 1/2 8.440 3.813 15,000 15,000 80-350 V0

Notes:
Available in two setting options: tubing set or control-line set
Available in three releasing options: straight shift and pull method, knock-out plug and pump method, punch and pump method
Available in various metallurgy, elastomers and thread connections to suit well conditions
Refer to individual specification sheets for additional details.
*Pending qualification testing
**Pending qualification - 8.5-in. special drift casing. Maximum casing ID 8.710
Contact Halliburton for additional information.
Aflas is a registered trademark of Asahi Glass Company

WellDynamics 3-13
MC Packers
Halliburton WellDynamics’ MC
packers, available for both production
(MC-1) and isolation (MC-0)
applications (no slips), are single-string,
cased-hole, retrievable packers
primarily designed for use in
SmartWell® completions in marginal or
mature assets.
Both MC production and isolation
packers have the facility to feed through
up to eight hydraulic or electrical
control lines, allowing communication
with other SmartWell equipment
without compromising the integrity of
the isolated zones. In some instances,
the MC production packer has been
used as an isolation packer below the
primary HF-1 production packer.
Features
• Simple, cost-effective design
• Feed-through for up to eight
control lines
• Tubing set
• Nitrile and HNBR packing element
Benefits
• Apply SmartWell technology in
marginal or mature assets
• Maintain zonal integrity
• Perform high pressure/tubing
pressure testing
• Achieve communication with laser
tools
Setting Mechanism
Both MC production and isolation
packers are tubing pressure set.
Incorporating a hydraulically activated
interlock system, the MC packers can be
adjusted externally prior to running in
the hole. The interlock system allows
the packers to be run in highly deviated
wells, eliminating the risk of presetting
due to casing.
3-14
Release Mechanism
The MC production packer is released
by the “shift-and-pull” method. Once
the primary packer is released, the MC
isolation packer can be retrieved simply
by pulling it straight out of the well.
Packing Element
The MC packer is fitted with a state-of-
the-art nitrile and HNBR packing
element similar to those used in
Halliburton WellDynamics’ high-
performance HF-1 packer. This element
offers robustness and excellent sealing
properties.
Nominal Conditions
The MC production and MC isolation
packers are designed for use in wells
with the following normal conditions:
• BHP < 5,000 psi
• Negligible H2S and CO2
BHT < 275°F
• ΔP 5,000 psi
Reliability
The MC production and isolation
packers have been qualified to an ISO
14310 V3 rating.
HAL33643
MC
Packer
WellDynamics
 Retrievable Feed-Through MC Packers

Maximum
Differential Required
Casing Casing Mandrel Maximum Maximum Across Working Working Setting ISO
OD Weight Size OD Bore ID Feed- Element Pressure Temperature Pressure Element 14310
Type in. lb/ft in. in. in. Through psi psi °F psi Type Rating

23 3 1/2 6.180 2.817 4,000 HNBR

7 8 5,000 5,000 75-275 V3
26-29 3 1/2 5.992 2.817 2,400 Nitrile
40 5 1/2 8.614 4.580 3,500 3500 3,500 HNBR V3
3 1/2 8.440 2.750 4,000 HNBR
722MC
Production 47 4 1/2 8.460 3.810 5,000 5,000 3,500 V3
Packer Nitrile
9 5/8 5 1/2* 8.455 4.590 8 75-275 4,000
3 1/2 2.825
53.5* 4 1/2 8.297 3.820 5,000 5,000 4,000 Nitrile V3
5 1/2 4.590
722MC 5 1/2 13-17 2 7/8 4.700 2.373 8 2,500 5,000 75-275 2,400 Nitrile V3
Isolation
Packer 7 26-29 3 1/2 5.980 2.885 8 2,500 5,000 75-275 2,400 Nitrile V3

Notes:
Packer is set only via the tubing.
Packer is released via straight shift and pull method
Metallurgy options: 4140 or 13Cr
Thread connections: Vam Top
Refer to individual specification sheets for additional details.
*Pending qualification testing
Contact Halliburton for additional information.

WellDynamics 3-15
Seal Stack Assembly
Halliburton WellDynamics' seal stack assembly isolates The device is capable of isolating zones with a differential
individual zones in SmartWell® intelligent completion pressure of up to 7,500 psi but, unlike the HF-1 packer range,
systems in applications where it is not possible or desirable to has no load bearing capability.
use packers for isolation.
Features
The seal stack assembly enables bypass of control lines to • Simple effective design
communicate with equipment installed lower in the • Multiple sets of bonded seals
completion string.
• Bypass for up to six control lines
Typical applications are gravel pack or ESS completions where • Field-proven
the seal stack assembly will stab into a polished bore to
provide isolation between different reservoir intervals in the Benefits
sandface completion. This ability is based on the use of a stack • Installs above ICVs and permanent downhole gauges
of robust bonded seal rings arranged along the assembly
• Isolates reservoir intervals without requiring a packer
length.
• Helps eliminate need for setting/release system
The seal stack assembly allows up to six independent control
lines to bypass, enabling control and monitoring of
equipment below, such as interval control valves and
permanent downhole gauges.
HAL30650

Seal Stack Assembly

3-16 WellDynamics
 Seal Stack Assembly
Maximum Hydraulic
Pressure Maximum Port
Maximum Minimum Maximum (Burst and Differential Pressure Thread Size and
Size Body OD Seal OD ID Length Temperature Collapse) Pressure Rating Type
in. in. in. in. in. °F psi psi psi (B x P)

4.75 2 7/8 in. 6.4 lb

4.695 4.826 2.382 83.640 275 10,000 7,500 10,000
(ECC) Vam Top
4.80 2 7/8 in. 6.4 lb
4.740 4.870 2.340 92.420 275 10,000 7,500 10,000
(ECC) New Vam
2 7/8 in. 6.4 lb
5.00 5.076 4.945 2.313 80.000 275 10,000 7,500 10,000
New Vam
3 1/2 in. 9.2 lb
5.80 5.770 5.876 2.945 88.923 275 10,000 7,500 10,000
New Vam
3 1/2 in. 9.2 lb
6.10 6.050 6.176 2.945 72.220 275 10,000 7,500 10,000
Vam Top
3 1/2 in. 9.2 lb
7.125 7.075 7.201 2.945 72.210 275 10,000 7,500 10,000
Vam Top
4 1/2 in. 12.6 lb
7.20 7.150 7.276 3.813 107.210 275 10,000 7,500 10,000
Vam Top
Notes:
Control lines are normally hydraulically spliced above and below the seal stack assembly. Control-line feed throughs are also available.
Number of feed throughs or hydraulic splices or both depends on the size of mandrel.
Seals are nitrile bonded 90 duro.
Contact Halliburton for additional information.

WellDynamics 3-17
Downhole Control Systems
Halliburton WellDynamics’ downhole control systems
provide a method of integrating the surface control system
(either manual or automated) with downhole SmartWell®
equipment.
• Capable of interfacing with multiple subsea control
vendors
• Infinitely variable control valve positioning
• Flow estimation derived from fundamental metrology

SCRAMS® Surface Controlled Reservoir Benefits

Analysis and Management System • Optimize reservoir performance by controlling multiple
reservoirs without intervention
The SCRAMS® system is a fully integrated control and data
acquisition system that allows the operator to remotely control • Enhance reservoir management through real-time data
the wellbore and obtain real-time pressure/temperature data acquisition
for each zone. This data feedback and accurate flow control • Remotely control the wellbore
capability allow the operator to optimize reservoir
• Obtain real-time pressure/temperature data for each
performance and enhance reservoir management.
reservoir interval
The SCRAMS system is ideal for onshore, platform, and subsea • Steer around faults for continued functionality using full
applications and is typically used to control the IV-ICV valve redundancy capability
for precise control of flow into or out of a reservoir interval. • Control multiple intervals from only one of the two
electro-hydraulic flatpacks through multi-drop
Features functionality
• Can be used to control Halliburton WellDynamics’
infinitely variable hydraulic flow control valves
• Can be used for land, platform, or subsea applications
Auxiliary Flat-Pack
Primary Flat-Pack Consisting of
Consisting of 1x Electrical Line
1x Electrical Line 1x Hydraulic Line
1x Hydraulic Line SAM Unit
Infinitely Variable
Interval Control Valve
Electrical Line
Hydraulic Line
Broken/Damaged Line

Damaged or
Broken Line
Damaged or Connection
Broken Line Re-established
via SAM™ Unit
HAL30655

Connection Re-established
via SAM™ Unit
SCRAMS® Surface Controlled Reservoir Analysis and
Management System

3-18 WellDynamics
Operation
The link from the control equipment located outside the well
to the downhole tools includes redundant hydraulic and
electrical buses in the form of control lines and electrical
conductors enclosed in a flatpack. The hydraulic control line
provides the hydraulic locomotive force to the SAM™ sensor-
actuated module tool, which in turn, using solenoid valves,
distributes this force to each side of the ICV piston. The
electrical conductor allows transmission of power and
communication signals from the well controller to all of the
downhole tools by means of the multi-drop telemetry system.
In order to simplify and increase the reliability of the cable
to the downhole tool interface, the SCRAMS™ system
adopts a signal-on power telemetry system. To further
enhance the downhole system survivability, the redundant
electric and hydraulic network is segmented (SegNet™
communications protocol).
WellDynamics
If any failure, either electric or hydraulic, develops in any
section of the network between surface and the downhole
tools, the SegNet communications protocol provides the
ability to steer around the failure, retaining full functionality
of the complete SmartWell® completion system.
SAM™ Sensor Actuation Module
The SAM™ tool provides the control and data acquisition
functionality for the SCRAMS system. The SAM tool
contains redundant electronics, each separately connected to
individual flatpacks, a hydraulic manifold to distribute
hydraulic power, and sensors for pressure/temperature
measurement. The SAM tool is the active component of the
SegNet infrastructure. Incoming electrical and hydraulic
buses are terminated into the SAM tool and exit to provide
communication to other SAM tools further down the
completion string. Solenoid valve and electrical switches
incorporated in the SAM tool allow isolation of any
potentially faulty sections of the network connecting the next
tool in the completion.
3-19
SmartPlex™ Downhole Control System
Halliburton WellDynamics’ SmartPlex™ downhole control Hydraulic In
system is an electro-hydraulic multi-drop system that Electric In
provides simple and reliable zonal control of multiple valves Three-Line
in a single wellbore with a minimum number of control Flatpack
lines. The SmartPlex downhole control system uses two
hydraulic and one electric line from the surface to remotely
and selectively actuate multiple downhole flow control
devices such as interval control valves (ICV). This makes a
large number of tubing hanger penetrations unnecessary and
reduces operational complexity and risk. SmartPlex™
Manifold
The SmartPlex system can control any flow control tool in
the field-proven Halliburton WellDynamics portfolio.
SmartPlex
Features Clamp
• Three control lines for up to 12 downhole devices or four
control lines for up to 24 downhole devices
• Minimal use of only passive and no active electrical Electric Out
components Hydraulic Out
• System can remain pressured when operating any of the
ICVs in the same direction, significantly decreasing ICV
actuation times
• Can be deployed with non-integrated systems and
fiber optics
• Supports “fail-as-is” device types
Interval Control Valve
• Independent of tubing or annulus pressure or sFrac™ Valve
• Can be used to position ICVs in choking applications

Benefits
• Helps reduce cost in multi-valve completions
• Faster activation time for valves
Three-Line
HAL32214

• Reduces rig time through greater facilitation of

completion installation and retrieval Flatpack

• Electro-hydraulic system provides high level of motive Control Module with

power to operate ICVs Clamp Assembly
• Allows the ICV to be closed in a single step
• Provides the ability to move the ICV from closed to any
choking position in a single step

3-20 WellDynamics
Application
The SmartPlex™ downhole control system is applicable for
any dry tree multi-zone completion requiring more than two
valves. When compared to the Direct Hydraulics system, the
SmartPlex system not only helps reduce the overall cost of an
intelligent completion, but also reduces the complexity
involved by minimizing the number of control lines required.
Qualification Testing
The SmartPlex control system has successfully passed
extensive in-house deep well simulation testing. The tool has
been cycled more than 10,000 times at 300°F (150°C) at
10,000 psi internally and 15,000 psi externally. A three-valve
system integration test with 10,000-ft control line was also
successfully conducted.

The SmartPlex system is ideally suited for long horizontal,

compartmentalized completions, in both cased or open hole,
where selective control of each interval is desired. Typically
this can be advantageous for selective stimulation control in
tight gas applications or in combination with a choking ICV
for drawdown optimization in production applications.

Operation
The SmartPlex system is a design that uses a simple passive
electrical switching method. Each valve is coupled with a
SmartPlex actuator module which allows selective and
remote control of each valve. Control lines consisting of one
electrical and two hydraulic lines run from surface and are
networked to each SmartPlex module. A signal down the
electrical line switches a solenoid at the desired module,
allowing hydraulic communication between the surface
control unit and the valve. By regulating the fluid volume in
combination with a time-domain control method, valves can
be incrementally positioned (choking) to allow for advanced
reservoir management.
HAL32215
HAL31805

The SmartPlex™ downhole control system provides a simple methodology for controlling up to 12 interval control valves.

WellDynamics 3-21
Digital Hydraulics™ Downhole Control System
The Digital Hydraulics™ system is an all-hydraulic, multi-
drop intelligent completion system that can direct any flow
control tool in the Halliburton WellDynamics portfolio,
providing simple and reliable zonal control for even the most
complex reservoirs. The Digital Hydraulics system allows up
to six flow control devices to be controlled from only three
hydraulic control lines, making a large number of tubing
hanger penetrations unnecessary.
Each flow control device is paired with a decoder that is
designed to respond to its own unique code and rejects all
other codes or sequences. Using this method, the
communication between the surface controller and the
downhole tools maintains its integrity—even when
conditions such as temperature changes, long control lines,
fluids, and leaks can cause other hydraulic communication
methods to fail.

Features The Digital Hydraulics system controls simple open/close

• High activation forces for flow control devices in interval control valves (ICV) and lubricator valves (LV) to
both directions provide on/off flow control from each zone.
• Three control lines for up to six downhole devices
• Four control lines for up to 12 downhole valves
Control Lines Pressure
• Can be deployed with non-integrated systems and From Surface
No Pressure
fiber optics
• No setting depth limitations
• All-hydraulic system
Decoder 1
• Supports “fail as is” devices
• Field-proven
• Independent of tubing or annular pressure ICV 1

Benefits
• Helps reduce control line costs
• Helps reduce rig time through greater facilitation of Decoder 2
completion installation and retrieval
• Fewer connections through tubing hanger
ICV 2
Operation
The Digital Hydraulics system design uses the logical absence
or presence of pressure (hydraulic code) to communicate To More
between a surface controller and the
HAL30644

Decoders
downhole tools.
Digital Hydraulics™
Existing pressure greater than 2,000 psi is represented by a “1”
System
and pressure less than 500 psi is represented by a “0.”
Depending on the pressure in the wellbore, a sequence of 1s
and/or 0s is communicated to the flow control devices within
the Digital Hydraulics system.

3-22 WellDynamics
Surface Control
The surface equipment for the Digital Hydraulics™ system,
Halliburton WellDynamics' SmartWell® Master™ supervisory
application, is designed as part of the Digital Infrastructure
system. A fully automated surface hydraulic system (SHS),
controlled from a central location allows control of the Digital
Hydraulics system from a local or remote control station.
Digital Hydraulics™ System
Number of Control Lines
Number of Double Acting Tools
Maximum Setting Depth
Temperature Rating
°C
Surface Control System
Maximum Operating Pressure
psi
Maximum Hydraulic Chamber Rating
psi
Facilities
Control Devices
Working Fluid
(currently qualifying for water-based control fluid)
WellDynamics
The SmartWell Master application translates Digital
Hydraulics system logic into standard central control room
operations. This translation allows the operator to easily
monitor and control multiple Digital Hydraulics
completion systems as well as an individual zone within an
intelligent well completion.
3
6
No practical limitations
4 - 135
Automated or manual
4,000 (6,000 test pressure)
10,000 - 15,000
Land, subsea, platform, or TLP
(currently qualifying for subsea)
Any Halliburton WellDynamics ICV
Synthetic hydraulic control fluid
3-23
Direct Hydraulics Downhole Control System
The Direct Hydraulics downhole control system uses direct
hydraulic control lines from the surface to remotely actuate
downhole flow control devices such as interval control valves
(ICV). The Direct Hydraulics system also provides on/off
variable control of flow into or out of reservoir intervals and
can be used in onshore, platform, or subsea applications.

Features
• Can be used to control all Halliburton WellDynamics
hydraulic flow control equipment
• Provides all-hydraulic control
• Networking option helps reduce number of control lines
required
• Operates as a closed-loop system
• Requires no setting depth

Benefits
• Controls reservoir intervals without costly intervention
• Helps eliminate dependence on mechanical or
pneumatic spring-return mechanism to open and
close ICV
• Use in onshore, platform, or subsea applications

Operation
A typical Direct Hydraulics system includes an ICV, an
Accu-Pulse™ hydraulic positioning module, and a zonal
isolation packer such as the HF-1 packer. The ICV is a
remotely operated control valve used to control flow into
or out of an isolated reservoir interval. Hydraulic control
lines are installed at the surface and are fed directly into the
ICV piston. For control of a single ICV, two control lines
are run from surface with one attached to the open side of
the piston and the other attached to the close side. Pressure
applied to one line, rather than to the other, drives the
piston to the corresponding position. Since the piston is
rigidly attached to the ICV opening mechanism,
movement of the piston operates the valve. This feature can
dramatically improve the ability to shift a sleeve which has
HAL30640

been stuck due to scale buildup.

Direct Hydraulics System

3-24 WellDynamics
Accu-Pulse™ Incremental Positioning Module
Halliburton WellDynamics' Accu-Pulse™ incremental
positioning module is a complementary control module
that provides incremental opening of a multi-position
interval control valve (ICV). The Accu-Pulse control
module allows the operator to control produced or injected
fluid rates to the desired quantity, greatly enhancing
reservoir management capabilities.
Operation
The Accu-Pulse module provides incremental movement of
a suitable ICV flow trim by exhausting a predetermined
amount of control fluid from the ICV piston. The capability
to recharge and exhaust the same amount of fluid
repeatedly allows the ICV flow trim to be accurately moved
through up to 11 predetermined positions.

The Accu-Pulse module works in tandem with either The Accu-Pulse module can communicate with either side
Halliburton WellDynamics' Digital Hydraulics™ or Direct of the ICV piston. It can drive the ICV open or closed. This
Hydraulics downhole control systems and with the HS-ICV ability provides incremental positioning in one direction
multi-position valve. with the ICV being driven to a fully open or closed position
when pressure is applied from the other direction.
Applications
The Accu-Pulse module provides effective incremental Reliability Testing
control of an ICV in a range of applications, such as: Extensive reliability and integration testing is performed
on the Accu-Pulse module to ensure accuracy and long-
• Internal gas lift
term performance.
• Waterflood
• Gas injection Long-Term Testing
• Commingled production The Accu-Pulse module has been long-term tested for:
• High temperature – up to 330°F (165°C)
Features
• High pressure – 10,000 psi
• Hydraulic, incremental control
• Flow-induced vibration
• Ability to close valve from any position in one press
cycle
• Provides up to 11 discrete positions with the
appropriate interval control valve

Benefits
• Enhanced reservoir management through control of
produced or injected fluids
• Helps provide accurate flow estimation and allocation
• Avoidance of reservoir drawdown
• High level of well control for internal gas lift,
HAL30629

waterflood, and commingled flow

Accu-Pulse™ Module

WellDynamics 3-25
Auxiliary Components

Concentric Hydraulic Disconnect Tool Running Options

Halliburton WellDynamics' concentric hydraulic
Halliburton WellDynamics' concentric hydraulic disconnect disconnect tool can be configured on location to provide
tool allows operators to disconnect from electric submersible three modes of operation:
pump (ESP) applications without having to pull the entire
completion—thereby saving rig time and costs. • Snap latch – Snap in/snap out
• Anchor – Snap in/rotate out to release
Compact in design, the concentric hydraulic disconnect tool
• Shear anchor – Snap in/shear to release
also enables reconnection and isolation of the tubing and
hydraulic umbilical to the lower completion when the tubing
is redeployed.

The concentric hydraulic disconnect tool features six

hydraulic control-line channels that provide communication
in a SmartWell® intelligent completion system. All six
channels are independent of each other.

Applications
• ESP pump applications
• Safety valve replacement
• Plug and abandonment options
• One and two-trip completions

Features
• Compact design
• Six hydraulic control-line channels (up to eight channels
available)
• Seal technology compatible with water and oil-based
fluids provides total isolation and prevents leakage
between the tubing and annulus
• No J-slot mechanism
• Straight string
• Built-in debris protection sleeve

Benefits
• Helps save rig time and associated costs
• Helps minimize risk and costs associated with workovers
• Protects against extrusion and blowout with durable,
high-performance seal
HAL30643

Concentric Hydraulic
Disconnect Tool Front View

3-26 WellDynamics
 Concentric Hydraulic Disconnect Tool
Size 3 1/2 in. × 7 in. 32 lb 4 1/2 in. × 9 5/8 in. 39 lb

Maximum OD
5.950 8.3
in.

Minimum ID
2.995 3.788
in.

Concentricity Upper and lower sections require concentric ID and OD

3 1/2 in. 9.3 lb/ft EUE 8 rd box or

Top Connection 4 1/2 in. 15.1 lb/ft VAM top box
9.2 lb/ft VAM top box

4 1/2 in., 10.5 lb/ft EUE 8 rd or VAM top

Bottom Connection 4 1/2 in., 10.5 lb/ft EUE 8 rd or VAM top
3 1/2 in., 9.3 lb/ft EUE 8 rd pin

Body Working Pressure

7,500 7,500
psi

Body Test Pressure

8,000 8,000
psi

C/l Pressure
7,500 7,500
psi

Metallurgy AISI 4140 18-22 RC / 80,000 psi yield per PES Spec A-005

Working Temperature
275 275
°F

Bypass Ports

Umbilical Hookup 6 x 1/4 in. hydraulic lines on each end of the tool

Tubing Seals TBA

C/l Fluids Red oil (MIL-H-5606) and water based

WellDynamics 3-27
Concentric Electric Disconnect
Halliburton WellDynamics’ concentric electric disconnect
allows operators to disconnect from the lower SmartWell®
system completion without having to pull the entire
completion string, thereby saving rig time and costs.
Compact in design, the concentric electric disconnect
enables reconnection and isolation of the tubing and
hydraulic/electrical umbilical to the lower completion when
the tubing is redeployed. The unique electric disconnect
design offers the capability to connect/disconnect from an
electrical line (I-wire connection) in addition to the standard
feature for hydraulic lines. This feature also provides the
ability to run permanent downhole gauges (PDG) as part of
the lower completion.

Applications
• ESP pump applications
• Safety valve replacement
• Plug and abandonment options
• One- and two-trip completions

Features
• Compact design
• Six hydraulic control-line channels
• One electrical line
• Seal technology provides total isolation and prevents
leakage between the tubing and annulus
• Straight string
• No J-slot mechanism

Benefits
• Helps save rig time and associated costs
• Helps minimize risk and costs associated with workovers
• Protects against extrusion and blowout with durable,
high-performance seal
HAL30635

Concentric Electric
Disconnect

3-28 WellDynamics
Running Options
The concentric electric disconnect can be configured on
location to provide three modes of operation:
• Snap latch – Snap in/snap out
• Anchor – Snap in/rotate out to release
• Shear anchor – Snap in/shear to release
Operation
The concentric electric disconnect features one electrical
control line and six hydraulic control-line channels
that provide communication in a SmartWell® intelligent
completion. All seven channels are independent of
each other.

Concentric Electric Disconnect

3 1/2-in. x 7-in. 32 lb
Size
(3593 size designation)
Maximum OD 5.950
in. (Concentric)
Minimum ID 2.995
in. (Concentric)

Concentricity Upper and lower sections require concentric ID and OD

3 1/2-in., 9.2 lb/ft VAM top box

Top Connection
(Upper half)
4 1/2-in., 13.5 lb/ft VAM top pin
Bottom Connection
(Lower half)
Body Working Pressure
7,500
psi
Body Test Pressure
8,000
psi
C/L Pressure
7,500 Maximum
psi
AISI 4140 18-22 RC / 80,000 psi yield per PES Spec A-005
Metallurgy
(Other materials may be substituted later)
Working Temperature 275 (135)
°F (°C) Maximum
1/8-in. NPT with Swagelok® tube fittings
Bypass Ports
(Others may be substituted to reduce OD)
1 × 1/4-in. electric line on each end of the tool
Umbilical Hookup
6 × 1/4-in. hydraulic lines on each end of the tool

Tubing Seals TBA

C/L Fluids Red oil (MIL-H-5606) and water based

WellDynamics 3-29
Splice Subs
The Halliburton WellDynamics splice sub connector is a
reliable, field-proven method of splicing two ends of flatpack
to facilitate repairs or lengthening. The splice sub also helps
protect the flatpack by securing it to the tubing.

The splice sub incorporates a two-piece robust splice clamp

with a key profile that locates into a groove machined in a
specially designed crossover. This arrangement ensures that
no vertical or rotational slippage of the clamp occurs during
installation or retrieval of the tubing string. The crossover is
made up directly to the tubing string.

Application
The splice sub is used in all SmartWell® completion systems
where a flatpack is deployed, including wells with chemical
injection, fiber optics, and surface-controlled subsurface
safety valve (SCSSV).

Features
• Fully compatible with standard Halliburton
WellDynamics FMJ metal-to-metal sealing fittings
• FMJs fitted to the splice sub are fully testable using a
standard FMJ test kit
• All splice connections are set within the body of the sub
for protection

Benefits
HAL33640

• Enables the splicing of up to four lines within a single

splice sub
• Allows free bypass of at least one bare control line Splice Subs
• Ease of assembly in the field

Connections
Halliburton WellDynamics FMJ connections are used to
make the splice connection, and these are retained within the
clamp body to protect the splices, flatpack, and control lines
from damage.

By using these metal-to-metal FMJ connectors, completed

connections can be pressure tested to ensure integrity.

The device also includes provision for bypassing at least one

additional bare 1/4-in. control line for operation of a
chemical injection valve or SCSSV.

The splice sub is available to suit different tubing

specifications and applications.

3-30 WellDynamics
Permanent Monitoring
Halliburton WellDynamics' permanent monitoring solutions
include the following:
• ROC™ permanent downhole gauges
• FloStream™ Venturi flowmeter system
HAL31448
• EZ-Gauge® pressure monitoring system ROC™ Gauge and Cablehead Connection

ROC™ Permanent Downhole Gauges Benefits

Halliburton WellDynamics’ ROC permanent downhole
gauges (PDG) help increase productivity through the life of
the well or reservoir by providing reliable, real-time
permanent monitoring of downhole conditions. Based on an
industry-standard, field-proven resonating quartz crystal
sensor, ROC gauges can be used for single or multi-zone
monitoring applications. In multi-zone applications,
variations of the standard gauge are available, along with
dual, triple, and quad splitter block assemblies for multi-
drop capabilities.
Halliburton WellDynamics has installed more than 1,000
ROC permanent gauge systems—both as standalone systems
and as integrated components of a SmartWell® completion
system—worldwide.
Applications
• Life of well production monitoring
• Life of field reservoir monitoring
• SmartWell completion system optimization
• Artificial lift optimization
• Obtain continuous pressure and temperature data
without the need for well intervention
• Enhance reservoir management
• Increase system reliability using stable pressure/
temperature measurements gained from state-of-the-art
testing
ROC Gauge Designs
• Quartz transducer
• Hybrid technology
• Maximum 200°C operating temperature
• Multi-drop capability – up to seven gauges at 30,000 ft
downhole cable
• Dual sensor feed-through capability
• Improved shock and vibration performance
• 0.75-in. OD slimline design available

Features
• Incorporates the most advanced high-temperature
electronics available in the marketplace
• Accurate quartz pressure/temperature sensor
• Designed for harsh environments up to 25,000 psi
• Dual-pressure testable metal-to-metal sealing
arrangement on both gauge and cable termination
• Reduced OD gauge design
• Multi-drop capability on single tubing-encased
HAL32151

conductor (TEC)
• Flow measurements for specific applications
• Hermetically sealed electron beam-welded design

ROC™ Gauge Environmental Chart

WellDynamics 3-31
Mechanical Arrangement
The ROC™ gauge mechanical arrangement consists of all
“wetted” parts manufactured from high-performance,
NACE-compliant corrosion resistant alloys (CRA).
Cable Termination
The cable termination is provided with a pressure-testable,
dual metal-to-metal ferrule seal arrangement for isolating
the downhole cable outer metal sheath from the well fluid.
Testing
The complete ROC gauge (sensor and electronic boards) is
independently calibration-checked in our calibration facility.
A calibration certificate is included with each gauge and is
provided before each installation.
New gauge designs are subjected to a Highly Accelerated
Lifetime Test (HALT) program. This program is a series of
controlled environmental stresses designed to ensure
stringent criteria are met for thermal shock, mechanical
shock, vibration, and thermal aging.
During manufacture, all ROC gauges are also subjected to
Environmental Stress Screening (ESS) to highlight any defect
in functionality prior to installation at the wellsite. This
screening method has proven to be far more effective than
“burn-in” techniques. All gauges are further subjected to
pressure tests at elevated temperatures during Factory
Acceptance Testing (FAT).
For more information on any of the details featured here,
please email us at welldynamics@halliburton.com.

ROC™ Gauge Family - Temperature Performance

Accuracy 0.5°C

Typical Accuracy 0.15°C

Achievable Resolution <0.005°C/sec

Repeatability <0.01°C

Drift at 177ºC <0.1°C/yr

ROC™ Gauge Family - Pressure Performance

Pressure Range 0 - 10,000 0 - 16,000 0 - 20,000 0 - 25,000
psi (bar) (0 - 690) (0 - 1100) (0 - 1380) (0 - 1725)

Accuracy
0.015 0.02 0.02 0.02
(% FS)

Typical Accuracy
0.012 0.015 0.015 0.015
(% FS)

Achievable Resolution <0.006 psi/sec <0.008 psi/sec <0.008 psi/sec <0.010 psi/sec

Repeatability
<0.01 <0.01 <0.01 <0.01
(% FS)

Response Time to FS Step

<1 sec <1 sec <1 sec <1 sec
(for 99.5% FS)

Acceleration Sensitivity
<0.02 <0.02 <0.02 <0.02
(psi/g – any axis)

Drift at 14 psi and 25°C

Negligible Negligible Negligible Negligible
(% FS/year)

Drift at Maximum Pressure and Temperature

0.02 0.02 0.02 0.02
(% FS/year)

3-32 WellDynamics
 ROC™ Gauge
ROC-150 ROC-175 ROC-200
Configurations
10K 16K 20K 25K 20K 25K

Single Pressure/ HAL32155

Temperature Sensor

3 3 3 3 3 3

Single Pressure/ HAL32156

Temperature Sensor +
Feed Through
3 3 3

Dual Pressure/ HAL32157

Temperature Sensor

3 3 3

Dual Pressure/ HAL32158

Temperature Sensor +
Feed Through

3 3 3

Dual Pressure/
HAL32159
Temperature Sensor
Fully Redundant

3 3

Dual Pressure/
Temperature Sensor HAL32160
Fully Redundant + Feed
Through
3 3

WellDynamics 3-33
ROC™ Gauge Mandrels
All Halliburton WellDynamics ROC™ gauge mandrels are
sized to match the tubing string in which they are to be run
in accordance with API 5CT. The gauge mandrel fully
contains the ROC gauge assemblies within the mandrel
body slots, protecting the gauges from damage. The gauge
mandrels are machined from solid bar stock and are
profiled to avoid snagging during run-in-hole operations.
The gauge mandrels are also provided with premium
threads to match that of the completion.
The gauges communicate with the production bore through
ports in the sidewall. The gauges are mounted in custom-
profiled locations on the mandrels, and a metal-to-metal seal
with elastomeric backup seals provides a high-confidence
permanent pressure seal between the mandrel and gauge.
Accuracy and Resolution
• Accuracy of +5% can be achieved, provided the limits of
the Venturi flowmeter principle are not exceeded
• Resolution of <0.1% of full scale
Operational Parameters
The Venturi flowmeter mandrel can be machined to a specific
profile or can incorporate a wireline-retrievable Venturi
flowmeter section, which can allow for:
• Changing of the Venturi flowmeter should the flow rate
change significantly
• Replacement should the Venturi profile become worn
• Removal of the restriction imposed should it become
necessary to carry out some well maintenance operation
below the flowmeter

All gauge mandrels are fully tested prior to delivery. This

testing includes:
• NDT - MPI to ASTM E709:94
• UT wall to ASME V SA V88
• Gauge-mount pressure testing
• Bore burst testing as per API 5CT to match that of the
tubing string
• High-pressure external testing on completed assembly
• Thread gauging and drift testing

FloStream™ Venturi Flowmeter

The Halliburton WellDynamics FloStream™ flowmeter
incorporates a Venturi flowmeter profile and two high-
accuracy ROC quartz pressure and temperature gauges. An
optional third ROC gauge can be added to enable continuous
calculation of downhole fluid density to be made.

Benefits
• Accurate downhole flow rate measurement
• No moving parts mean high reliability
• Based on proven ROC permanent gauge technology
• Wireline-retrievable Venturi section option allows
measurement of changing flow rates without a workover
• Absolute pressure measurement allows redundancy in
pressure measurement and a wide flow rate
measurement window
• Minimum pressure loss over whole system

3-34 WellDynamics
EZ-Gauge® Permanent Pressure Monitoring System
Halliburton’s EZ-Gauge® permanent pressure monitoring
system accurately monitors downhole pressure without
downhole power, electronics, or moving parts. Using capillary
tubing as the measurement mechanism, the EZ-Gauge system
is a reliable, effective tool for long-term monitoring in
extremely harsh environments where electronics will
not function.

Features
• Capillary tubing negates need for costly downhole
electronics
• Durable pressure sensor is resistant to harsh
environments
• No temperature limitations

Benefits
• Check system accuracy without well intervention
• Interchange pressure acquisition systems on user needs
• Minimize drift and accuracy problems by calibrating
pressure transducer at any time
• Validate system function through a series of chamber
checks and purge techniques
• Run pressure system in conjunction with distributed
temperature systems
• Run system as retrievable, permanent, or semi-
permanent

Operation
The EZ-Gauge system utilizes a small diameter capillary
tubing line connected to a downhole pressure chamber. The
pressure chamber is placed downhole as an integral part of
HAL17679

the completion or run on coiled tubing or spooled in the hole

similar to slickline. A pressure transducer is attached to the
capillary tubing at surface. The system is purged with a light,
inert gas, usually helium.

Once the EZ-Gauge system is installed, the pressure at surface

EZ-Gauge® Permanent Pressure Monitoring System
is corrected for the additional hydrostatic pressure of the
helium gas column in the capillary tube. The hydrostatic
correction includes an iterative process to calculate the
helium density as a function of the entire well temperature
and pressure.

This provides an accurate means of measuring downhole

pressures without the inherent difficulties experienced when
using downhole electronics.

WellDynamics 3-35
EZ-Gauge® System Components
• Downhole Chamber and Sensing Point
The downhole chamber and sensing point can be installed
in a number of different ways.
- Chamber and capillary tubing can be installed
permanently by incorporating them into the casing
and cementing into the well. Temporary darts isolate
chamber while casing is run and cemented in place.
- The downhole chamber can be built into the
production string and can be placed above or below
packer arrangements for monitoring annulus or
tubing pressure.
- For short-term applications, the chamber is attached
to the end of a capillary tube that can be run in the
well in a manner similar to wireline. The chamber is
sized based on well operating pressure and
temperature, the well depth, and the capillary tubing
size used.
3-36
• Capillary Tube
Capillary tube size and type is determined by well
pressures and conditions. Various tube sizes react
differently depending on pressure range and changes.
• Surface Instrumentation
The available surface instrumentation ranges from basic
pressure readouts to advanced data acquisition devices
with memory and real-time telemetry capabilities.
The EZ-Gauge® system can be used with something as
simple as a dial gauge for general pressure display, or as
advanced as a high accuracy quartz transducer system that
stores and/or transmits data to a central storage and
monitoring point.
WellDynamics
Chemical Injection System
Halliburton WellDynamics' chemical injection applications Dual Check Valve
include: The Halliburton WellDynamics chemical injection systems
include dual check valves, providing redundant checks (one
• Scale
hard seat and one soft seat). The connection to the chemical
• Asphaltines injection line uses primary and backup ferrules to provide
• Emulsions improved sealing and physical strength. The check valve body
• Hydrates is a welded construction to further reduce the possibility of
tubing/annular leak.
• Defoaming
• Paraffin The check valve is available in a variety of materials to best
• Scavengers suit well conditions with externally testable connections to
• Corrosion reduce makeup time.
• Demulsifiers
Control Line, Chemical Injection Lines, and Clamps
There are two variations of chemical injection mandrels: Multi-line conveyance is supplied as a standard service and
includes all necessary spooler units, hydraulic slip rings,
• Deep-set nipple mandrel – A robust one-piece machined pumps, filters, and sheave wheels. Halliburton WellDynamics
design utilizing the same design criteria as the can provide full pump capability for operations during
permanent downhole gauge mandrel for use in tripping in hole and for commissioning the well. Control lines
deepwater or critical applications and chemical injection lines are available in all common
• Welded pup nipple mandrel – Designed for use in materials with tubing sizes and wall thicknesses to suit
shallow set, non-deviated wells, or land applications all applications.

Features
• Dual check valve (burst disk option available)
• Externally testable connections
• Welded construction check valve body
• Check valve material to suit application
The lines can be provided bare, encapsulated with other lines,
or with a tubing-encapsulated connector (TEC) line. Lines
are supplied fluid filled, flushed, and filtered to the required
NAS standard. Cast steel or press steel clamps are used to
protect the control lines.

Benefits
• Subsea, platform, and land applications
• Cost effective
• Multi-line conveyance

WellDynamics 3-37
Digital Infrastructure

Halliburton WellDynamics' digital infrastructure system SmartWell® Master™ Supervisory Application

enables operators to:
Halliburton WellDynamics' SmartWell Master supervisory
• Monitor and control permanent downhole gauges (PDG) application for the digital infrastructure product line
• Remotely control and configure downhole interval provides a central point of control and monitoring for
control valves (ICV) SmartWell and permanent monitoring systems.
• Monitor and control surface sensors and instruments
The SmartWell Master application is based on the
• Connect to distributed control systems and other third-
ICONICS GENESIS32™ web-enabled human machine
party systems for monitoring and control
interface (HMI)/supervisory control and data acquisition
• Provide remote power and communications for (SCADA) software running on the Microsoft® Windows®
Halliburton WellDynamics' SmartWell® and permanent operating system.
monitoring systems where no infrastructure is available
• Interface with field controllers provided by a variety Features
of vendors • Web-based HMI/SCADA visualization
• Modular tool suite for visualization, HMI, and SCADA
The digital infrastructure portfolio consists of the
following electrical and hydraulic sub-systems and • GENESIS32 OPC-To-The-Core Technology™ system
applications: • Visual OPC alarming and event notification
• SmartWell® Master™ supervisory application – Provides • OPC connectivity
a central point of control and monitoring for SmartWell • Extensive diagnostics and analysis capabilities
and permanent monitoring systems
• Powerful data-mining technology
• XPIO 2000™ data acquisition and control unit – Allows
operators to monitor and control downhole gauges and • Custom configuration utility
topside instrumentation • International language switching and global aliasing
• UACU+ system – Larger variant of XPIO 2000 system • Visual control replay traceability playback
that enables monitoring of up to 20 wells/40 gauges
• Surface hydraulic system – Designed to supply Benefits
pressurized hydraulic fluid to downhole SmartWell • Control SmartWell downhole equipment from central
systems and provide automatic and manual control of location
downhole ICVs • Interfaces with external systems, including third-party
• Subsea interface cards – Allow users to monitor PDGs computers and distributed control systems
and control Halliburton WellDynamics' SCRAMS®
system completions in subsea applications. The cards
reside in pods provided by subsea control system vendors
• Remote power systems – Designed to support
Halliburton WellDynamics' digital infrastructure data
acquisition and control systems in areas where
conventional power and, in some cases, communications
are unavailable, unreliable, or cost-prohibitive
• SoftFlow™ data analysis and calculation application –
Provides well and zonal flow rate estimations
• Surface positioning system – Provides control of
downhole ICVs without downhole control devices

3-38 WellDynamics
External System Connectivity Modules
A custom external control module allows the The SmartWell Master application features several modules
SmartWell® Master™ application to connect to an external that can be enabled according to the operator's specific
system such as a third-party computer or DCS for control needs, including:
and data handoff. Resource locking is utilized to ensure
• HMI
control is available from either the SmartWell® Master™
application or the external system. Both OPC and Modbus® • Historical data
versions are available. • External OPC interface
• Remote client
Displays
The SmartWell Master application features standard displays • Alarms and events
specifically designed for: • Microsoft .NET helper programs, such as calculation
engines and external Modbus® data link modules
• Hydraulic supply modules
• Well control modules SmartWell® System Configuration
• Permanent downhole monitoring A custom configuration utility allows project-specific
• Alarming SmartWell systems to be built up in the SmartWell Master
• Trending application by dragging and dropping standard functional
modules.
A well configuration panel, a standard feature on the left-
hand side of the screen, shows which wells are configured for Trending
the project. A standard alarm banner, located at the bottom Trending can be carried out in real time or configured from
of the screen, displays the most recent real-time alarms which historical data.
have been raised.
Modbus is a registered trademark of Schneider Automation, Inc.
Tabs at the top of the screen allow easy switching between
displays. Various hardware configurations are available,
including standalone PC and rack-mount server with
retractable VDU/keyboard/mouse unit.

Hydraulic Supply Module Screen

WellDynamics 3-39
 Well Control Module Screen

SmartWell® Configuration Utility Screen

3-40 WellDynamics
SoftFlow™ Virtual Flowmeter
Halliburton WellDynamics’ SoftFlow™ virtual flowmeter is a • Calculation engine incorporates:
data analysis and calculation program that provides well and - Choice of analytical or numerical choke models to
zonal flow rate estimation and allocation in real time. estimate and allocate subsurface flow rates

Traditional asset production information is often based on
data acquired intermittently from individual well tests. The
SoftFlow application provides real-time estimates for
continuous reporting of daily production on a per-well and/
or per-zone basis. No additional equipment is required for a
SmartWell® completion system.
The SoftFlow application draws information from
downhole sensors as well as attributes from interval control
valves (ICV), such as HS-ICVs used in SmartWell
completion systems.
SoftFlow Application Requirements
• Intelligent well completions with ICVs, annulus, and
tubing sensors for every zone
• Dynamic Field Data Management System (FDMS)
interface to provide data and receive results from the
SoftFlow application
• Standard Human Machine Interface (HMI) to configure
the SoftFlow flowmeter for real-time operations and a
computer to use the SoftFlow application offline
Features
• Inputs can be configured for field and well levels
including well completion architecture, fluid
composition (PVT tables), and ICV attributes
• Calibration for unique well conditions using well test
data (shown to calibrate to 90% accuracy of actual flow
rate measurements)
• Enables oil and water production scenarios (gas
capability in future release)
• Configurable without well downtime or production
interruption
- Tubing performance, nodal analysis, and Inflow
Performance Relationship (IPR)
Benefits
• Asset Management
- Quickly helps identify wells with production problems
and implements corrective actions to restore
production
- Real-time reservoir information for asset optimization
- Helps improve production accounting and aids
compliance with regulatory reporting requirements
• Real-Time Operations
- Enables production accounting in real time
- Real-time monitoring of individual well and asset
performance
- Offers real-time well optimization (model, measure,
and optimize)
- Allows viewing of zonal flow for commingled wells in
real time
- Allows viewing of in-situ multi-phase flow estimates
in real time
• Data Management
- Calculation engine tolerates erratic or missing
sensor data
- Data analysis for back allocation (offline mode)

Field/Project Information Well Information Zone Information

1. Field information (single or multiple) 1. Well type 1. Zone PVT

2. Data management and quality 2. Well properties and architecture 2. ICV Specification
3. Define calculation parameters 3. Depth of sensors and ICV’s 3. Node definition
4. Units of measurements 4. Well administration
HAL32364

Information Chart

WellDynamics 3-41
 HAL32365

SoftFlow™ Screen Shot

HAL32363

SoftFlow™ Application Management System

3-42 WellDynamics
Surface Positioning System
Halliburton WellDynamics surface positioning system
provides a methodology to incrementally control the
downhole interval control valve (ICV) position in each zone
through the Halliburton WellDynamics surface hydraulic
system (SHS) without the need for downhole control
devices. It is implemented by calibrating and moving ICVs
from the surface with the help of an algorithm embedded
into the SHS controller.

With this method, a specific pressure is applied for a specific

time to one side of the ICV to cause it to move the desired
increment, thus exposing or closing a number of flow ports.
At the same time, compensating pressure is applied to other
ICVs to keep them at their current position.

The surface positioning system is a reliable, cost-effective

solution to move downhole ICVs to the desired choke open
or close position without the need for reset.

Features
• Implemented through algorithms embedded into the
SHS controller; no extra hardware is needed for the
automated SHS
• Can be integrated into the SmartWell® Master™
supervisory application
• Maintains other ICVs in their current position by
applying compensating pressures
• Can be used for wells with ICVs up to 10,000 ft deep;
HAL32162

applications out of this range can be reviewed on a

project-by-project basis
Surface Positioning of ICVs
• Can be used for a well with a configurable number
of ICVs
• Can be used for completions with a common close line
as well as independent open and close control-line
configurations
• User-friendly interface
HAL32219

Surface Positioning Sequence

WellDynamics 3-43
Benefits
• Provides incremental ICV position control from surface
without the need for downhole control devices, thereby
reducing system cost
• Provides ability to incrementally position an ICV in
either direction (open or close) without the need to close
the ICV first
• Requires less time to perform incremental moves than
systems using downhole control devices for this purpose
• Provides a flexible and configurable number of discrete
choke positions for an ICV
• Can be applied to new or existing direct hydraulics ICV
installations controlled from an automated SHS
HAL32163
SmartWell® Master Surface Positioning Screen
3-44
Surface positioning system calibration involves
determination of downhole response delay through
simulation software. Accuracy depends upon correct
information about the well completion configuration and
control fluid. Well condition changes require recalibration of
the surface positioning system to maintain accuracy.
The surface positioning method can provide incremental
control of an ICV in a range of applications, such as:
• Auto-gas lift
• Waterflood
• Gas injection
• Commingled production
WellDynamics
Remote Power Systems
For circumstances in which conventional power is Solar Photo Voltaic (SPV) Systems
unavailable, unreliable, or cost-prohibitive, Halliburton SPV systems convert sunlight to DC electricity and are the
WellDynamics offers a wide variety of remote power systems. preferred choice in most circumstances. Solar power can be
Each system is designed to support Halliburton used in conjunction with wind, TEG, or gen-set systems.
WellDynamics' digital infrastructure data acquisition and
control systems, including: Wind Generators
• XPIO 2000™ series of data acquisition and control units Modern electrical windmills harness wind power that can
complement solar power in conditions with intermittent
• Surface hydraulic system
sunlight. Regular maintenance and repair are required.
• OptoLog® DTS CE fiber-optic system
Thermoelectric Generators (TEG)
Depending on site conditions and available resources, TEGs burn natural gas and are extremely reliable when
operators can choose from solar, wind, thermoelectric natural gas is readily available. They can also be a good
generator (TEG), engine generator-set (gen-set), or DC-UPS supplement to solar power. A separator is normally required
systems, either individually or in combination. Systems if the gas is “wet.”
utilize existing local resources and enable wireless
communication to remote locations. Offshore systems DC-UPS
employ solar power with wind power backup. DC-UPS is recommended for situations in which power is
dirty, intermittent, or unreliable. Additional filtering and
The remote power systems employed by Halliburton surge suppression are offered in addition to backup.
WellDynamics are completely self-contained, pre-assembled,
and tested prior to shipment and are specifically tailored Engine-Generator Set (Gen-Set) Systems
for the electrical load and climatic conditions of each
Gen-set systems use conventional fuel to charge a large
particular site.
battery bank. They can be used to supplant solar power and
to charge batteries in temporary applications or in
Reliability
circumstances in which weather extremes make other
Health and safety margins are built into each remote
options unattractive.
power system in order to ensure high reliability and
continuous operation. Like all Halliburton WellDynamics
equipment and electronics, the remote power systems are
pre-wired inside custom enclosures and are fully factory-
acceptance tested prior to shipment. Systems are warranted
for five years.

Choosing the Appropriate Remote Power System

Among the most crucial considerations related to choosing
an appropriate remote power system is the year-round
availability of sunlight. Every remote power system must be
able to perform reliably during even the most inclement
weather. Accurate load information is also critical,
particularly if communications equipment is included.

In general, solar photo voltaic (SPV) cells are the preferred

method for providing remote power because of their
simplicity, reliability, and cost-effectiveness. The solar-panel/
battery combination is determined by accurately calculating
the total power consumption of the data acquisition and
control equipment and then sizing the system based on the
worst weather conditions. A safety margin is included.

WellDynamics 3-45
XPIO 2000™ Data Acquisition and Control Unit
Halliburton WellDynamics' XPIO 2000™ data acquisition
and control system allows operators to monitor and control
downhole gauges and topside instrumentation. Acquiring
data at a rate of 0.5 seconds per gauge, the XPIO 2000 system
is available in a range of capacities, from 1 well/4 gauges to
4 wells/8 gauges. A larger variant within the XPIO 2000 range
is the UACU+, which extends capacity up to 20 wells/
40 gauges for a single unit. The UACU+ is fitted with a
permanent downhole gauge interface card (PDGIC) module
for each downhole channel.
Downhole cable inputs are independent and fully isolated.
Features
• Five channels of 4-20mA analog inputs (12-bit)
• Four channels of 4-20mA analog outputs (16-bit)
• 4MB of flash memory
• Modbus® RTU protocol support via RS-485 or RS-232
port, or via TCP/IP port
• Modem communications support via the RS-232 port
• Two relay contacts
• Communications programs that allow full configuration
of the unit
Benefits
• Control Halliburton WellDynamics' permanent
downhole gauges (PDG), including the ROC™ family,
SmartLog™ gauges, and surface instruments
• Store and display data from PDGs and surface sensors
• Interface with external systems, including third-party
computers and distributed control systems
Analog Inputs
The XPIO 2000 system features five channels of 4-20mA
inputs (12-bit) that are fully configurable using the
XPIO 2000 PC program. Users can set the offset, span, and
units of measure, and then can choose to monitor them on
the display or log them into memory.
Analog Outputs
The XPIO 2000 system features four channels of 4-20mA
outputs (16-bit). Users can select the pressure, temperature,
span, and offset of a permanent downhole gauge, and the
XPIO 2000 system will drive the translated value onto an
output as it is decoded from down hole.
Modbus is a registered trademark of Schneider Automation, Inc.
3-46
Memory Logging
The XPIO 2000 system comes standard with 4MB of flash
memory. A SanDisk CompactFlash® card option extends the
memory by 2GB.
The 4MB memory can hold pressure and temperature data
from one gauge at one-minute updates for more than three
months. The 2GB option extends memory capacity to hold
pressure and temperature data from two gauges at
one-second updates for more than a year.
Data is retrieved via an RS-232 port using the supplied PC
program or by file transfer protocol (FTP) over the TCP/IP
link and can easily be imported to other applications such as
a spreadsheet. Data is logged to memory at a maximum rate
of once per second.
Both the standard XPIO and UACU+ are available in
NEMA4X enclosure and 19-in. rack mount versions. The
19-in. rack mount UACU+ has a 10-well/20-gauge capacity.
Serial Communications
The XPIO 2000 system supports Modbus® RTU protocol via
its RS-485 or RS-232 port or via its TCP/IP port. These
interfaces are fully configurable in terms of parity, baud rate,
etc. As a slave device, the XPIO 2000 system provides gauge
data (i.e., pressure and temperature) that can be polled as
well as data from any of the 4-20mA inputs. Time and date
are also available.
Modem Support
The XPIO 2000 system supports modem communications
via the RS-232 port. Users may dial into the unit using
the supplied PC program, or use the port to talk to the
Modbus system over a radio modem, cellular modem, or
regular modem.
Pressure-Controlled Relay Contacts
The XPIO 2000 system comes with two relay contacts
(1/2A at 115VAC) which are controlled by software. When a
selected gauge's pressure rises above or falls below a set
pressure, the contact is closed. This feature is ideal for alarms
and/or pump control.
Web-Installed PC Application
The XPIO 2000 system comes with a web-installed
application that provides for full configuration of the unit as
well as data memory retrieval, real-time logging of data to
the computer hard drive, and real-time data trending.
The application communicates with the XPIO 2000 system
via a standard RS-232 port and runs on the Microsoft®
Windows® 2000/XP/Vista operating system.
WellDynamics
Operating Information Enclosure
• 110/250 VAC • NEMA-4 type water resistant
• 10-36 VDC unit available • Anodized aluminum
• 14W power consumption plus 1W per gauge for XPIO • 19-in. rack-mount option
• 10W power consumption plus 2W per PDGIC plus 1W
per gauge for UACU+ Variants
• XPIO 1 well/4 gauges
• -10°C to 85°C operation
• XPIO-DT 2 wells/4 gauges
Gauges Supported • XPIO-QT 4 wells/4 gauges
• ROC™ family of permanent downhole gauges • XPIO+ 1 well/8 gauges
• SmartLog™ cost-effective gauges • XPIO-DT+ 2 wells/8 gauges
• EZ-Gauge® permanent pressure gauges • XPIO-QT+ 4 wells/8 gauges

Communication Ports • UACU+ 20 wells/40 gauges

• 2 × RS-232 • UACU+ 19-in. rack 10 wells/20 gauges
• 1 × RS-485
• 10-BASE-T option

Port Usage Options

• One RS-232 dedicated to XPIO PC program
• Modbus® RTU
• Modem support (radio/cell)
• TCP/IP via ethernet (optional)

Inputs
• Five 4-20mA inputs (12-bit)
• One 16-bit A/D (tool current)

Outputs
• Four 4-20mA outputs (16-bit)
• Two pressure-controlled relays

Memory
• 4MB flash for data logging
• 2GB SanDisk CompactFlash® option (standard
on UACU+)
HAL31424

XPIO Data Acquisition and Control Unit

Modbus is a registered trademark of Schneider Automation, Inc.

WellDynamics 3-47
Hydraulic Systems
Halliburton WellDynamics’ surface hydraulic system (SHS)
supplies pressurized hydraulic fluid to downhole interval
control valves (ICV) located in the well. It also retrieves
pressure and temperature data from Halliburton
WellDynamics’ permanent downhole gauges (PDG).

A standalone self-contained unit, the SHS consists of an

electro-hydraulic unit capable of delivering pressurized fluid
up to 10,000 psi to the SmartWell® equipment. It is housed
in a single stainless steel enclosure which includes one main
hydraulic supply module (HSM) and up to six well control
modules (WCM) with expansion capabilities.

The digital infrastructure system features a range of surface

hydraulic systems designed to meet every environment.
• The integrated system consists of the SmartWell®
Master™ supervisory application and an SHS consisting
of a hydraulic supply module and one well control
module per well. Data acquisition and control can be
managed either locally (by keypad or portable device
such as a laptop computer or PDA) or remotely.
Hydraulic System
• The automated system is an SHS which includes a
hydraulic supply module and one well control module Modules
per well. Data acquisition and control can be managed The basic SHS contains the following modules:
either locally (by keypad or portable device such as a
• Hydraulic supply module
laptop computer or PDA) or remotely.
• Well control modules
• The manual system consists of the same basic hardware
as the automated system but does not provide for
Automated systems, in addition to the hydraulic supply and
automated or remote control. Manually operated valves
well control modules, contain:
are used throughout.
• Hydraulic control unit
In subsea applications, SmartWell system control is provided • Well control units
by hydraulic functionality from the third-party subsea
controls company. The SHS is designed for hazardous area applications,
including IEC/Cenelec Zone 1 (ATEX category 2).
Features Automated systems can be controlled and monitored
• A variety of physical configurations for well type, remotely by the SmartWell Master supervisory application
number of zones, and completion details or from a third-party computer by the Modbus® system
• Modules that allow for remote control and monitoring over TCP/IP communications to the programming logic
by the SmartWell Master supervisory application controllers (PLC) in the hydraulic control and well
control units.
Benefits
• Supply pressurized hydraulic fluid to downhole interval In one-well cabinets, the HSM and WCMs are combined into
control valves a single unit. For automated systems, hydraulic control and
well control units are also combined.
• Retrieve pressure and temperature data from PDGs
Modbus is a registered trademark of Schneider Automation, Inc.

3-48 WellDynamics
The hydraulic control unit/well control unit firmware,
developed in IEC 61131-3 standard language, automates the
sequences and levels of pressure required to operate the
SmartWell® completion, and receives feedback from the ICV
movement from surface sensors.

Surface Hydraulic System Enclosure Features

• 316 SS, IP56/NEMA4X
• Removable latching doors
• Sloped drip pan
• 4X lifting eyes, multi-lift capable
• Ventilation louvers
• Ergonomic design
• Plexiglass doors
• Durability for harsh environments
Hydraulic Supply Module (HSM)
The hydraulic supply module (HSM) provides control fluid
to the well control module at the required pressure and
cleanliness. Material selection for some HSM components
may change according to the type of pressure and control
fluid used.
The HSM contains the tanks necessary to store and filter
control fluid. For optimal performance of downhole
equipment, all HSM designs are provided with a
recirculation capability for managing control fluid
cleanliness. Although the standard product contains two
tanks and two pumps, several variations—including one
tank and one pump—are available, depending on the
number of wells and operational philosophy.
The HSM provides all the electrical/hydraulic connections
for connection to the well control modules. The HSM
controls and manages system operation manually (switches)
or automatically (pressure transmitters and PLC). In
automated systems, the hydraulic control unit houses the
PLC and its accessories.
Hydraulic Supply Module
Well Control Module (WCM)
A well control module (WCM) provides a means of applying
pressure sequences to hydraulic control lines and therefore a
way of manipulating the downhole tools. Pressurization and
venting of the control lines are achieved by manual or
automatic supply/block/vent of directional control valves.
Designed for both reliable performance in the target
environment and for quick installation for future expansion,
well control modules are interchangeable modules that can
be combined with the same cabinet for multi-well
applications, providing a flexible base for future expansion.
In automated systems, each WCM is controlled by a
dedicated well control unit which can be fitted with an
optional permanent downhole gauge interface card (PDGIC)
module for communication with downhole gauges in
the well.
The number of hydraulic lines required to operate a
particular SmartWell completion system is dependent on the
chosen control system (Halliburton WellDynamics’ Digital
Hydraulics™ or Direct Hydraulics systems) and the number
of downhole valves in the well.

The hydraulic supply module consists of:

• Clean supply reservoir (typically 95 L)
• Return reservoir (typically 220 L)
• Main hydraulic supply pump
• Recirculation pump
• Accumulator (up to 10,000 psi)
• Filters (1μm, NAS1638, Class 6)
• Relief valves
• Tubing/fittings (up to 10,000 psi rated)
• Hydraulic control unit junction box

WellDynamics 3-49
Additional external ports are included for connecting chart Physical Configurations
recorders and an external hydraulic supply. A well control Halliburton WellDynamics’ surface hydraulic system comes
module contains the following components: in various physical configurations, depending on well type,
• Solenoid directional control valves (DCV) number of zones, and completion details. For example:

• Pressure transmitters (24VDC, 4-20mA) • Six-well cabinet

• Hydraulic pressure gauges (up to 10,000 psi) • Two-well cabinet
• Three-way manual control valves • Four-well expansion cabinet
• Relief valves and bleed valves • One-well cabinet
• External connection bulkhead • Portable unit
• Well control unit junction box (with optional PDGIC)
Both automated and manual versions of the surface
hydraulic system are available.

Well Control Module

3-50 WellDynamics
Subsea Interface Cards
Halliburton WellDynamics offers a range of subsea interface
cards that enable users to monitor permanent downhole
gauges (PDG) and control SCRAMS® surface controlled
reservoir analysis and management system completions.
Each subsea interface card resides in the pod provided by the
respective subsea controls vendor.
VetcoGray Dual Gauge Interface Card
Halliburton WellDynamics' VetcoGray dual gauge interface
card is compatible with the VetcoGray-type SEM2000 subsea
control module, which features a single downhole channel
that provides communications and power to the ROC™
family of gauges. It operates in either “Analog Gauge” or
“Digital Gauge” mode.
The card has been subjected to an extensive environmental
qualification program, including tests for:
• Temperature soak
• Temperature cycling
• Sine swept vibration
• Random vibration
• Non-operational shock
Functional card integration testing in the SEM2000 pod was
carried out at VetcoGray's premises in Nailsea, U.K. The card
has been deployed in the VetcoGray pod on major projects
for various operators, including Statoil and ENI.
Cameron Dual Gauge Interface Card
Halliburton WellDynamics' Cameron dual gauge interface
card is compatible with the generic Cameron subsea pod.
Featuring a single downhole channel that provides
communications and power to the ROC™ gauge family,
the card can operate in either “Analog Gauge” or “Digital
Gauge” mode.
Cameron dual gauge interface card firmware includes a
timeout feature on the gauge communications, ensuring the
card will disconnect power to the downhole gauges if the pod
processor has not communicated with the card for more than
the timeout period. This feature is important in Cameron
dual-SEM pods, where gauge outputs from the interface card
in each SEM are connected together.
The card has been subjected to an extensive environmental
qualification program, including tests for:
• Temperature soak
• Temperature cycling
WellDynamics
• Sine swept vibration
• Random vibration
• Non-operational shock
The card underwent extensive integration testing to
Cameron procedure X065418-07-01 at Cameron's premises
in Celle, Germany.
FMC Dual Gauge Interface Card
The Halliburton WellDynamics' FMC dual gauge interface
card is compatible with the FMC KS150 subsea electronics
module. The card features a single downhole channel that
provides communications and power to the ROC gauge
family and can operate in either “Analog Gauge” or “Digital
Gauge” mode.
The FMC card was subjected to an extensive environmental
qualification program, including tests for:
• Sine swept vibration
• Shock
• Thermal cycling
• Thermal dwell
The card underwent extensive integration testing at the FMC
premises in Kongsberg, Norway. An older card design, the
FMC digital gauge interface card, is still used exclusively in
Gulf of Mexico projects for a major customer. It has a single
downhole channel providing communications and power to
ROC digital gauges.
Aker Solutions Dual Interface Card
Halliburton WellDynamics' Aker Solutions dual gauge
interface card is compatible with the Aker Solutions iCon
(formerly 5th Generation) subsea control module. It has a
single downhole channel, providing communications and
power to the ROC family of gauges and can operate in either
“Analog Gauge” or “Digital Gauge” mode.
Unlike other interface cards, the Aker Solutions dual gauge
interface card uses a Hypertac® edge connector rather than a
DIN41612 Euro style connector. The card was subjected to
electromagnetic compatibility qualification testing specific to
Aker Solutions requirements, including:
• Emissions
• Immunity
• Electrical fast transients/burst immunity
Hypertac is a registered trademark of Smiths Interconnect.
3-51
Functional integration testing of the card in the iCon pod
was carried out at Aker Solutions’ premises in Aberdeen,
U.K. The card has also been deployed in the iCon pod on
major projects.
Dril-Quip Dual Gauge Interface Card
The Dril-Quip dual gauge interface card is the same card,
9670-6050, used by FMC. It was qualified in Houston, Texas,
with the Dril-Quip subsea control system provided by
Perry Slingsby.
Intelligent Well Interface Standard (IWIS) Card
Halliburton WellDynamics' IWIS card for monitoring of
permanent downhole gauges has been qualified with
VetcoGray, Cameron, FMC, and Aker Solutions and has been
qualified to IWIS environmental stress screening (ESS)
standards with tests for:
• Sine swept vibration
• Random vibration
• Physical shock
• Thermal soak
IWIS systems are based on transparent communications
between the IWIS card in the subsea pod and the intelligent
well computer (IWC) located topside. Consequently, it is
essential that a Halliburton WellDynamics IWC be provided
to communicate with any Halliburton WellDynamics IWIS
subsea card.
Subsea SCRAMS® Card
Halliburton WellDynamics offers a subsea interface card for
subsea SCRAMS® installations. This card, installed in the
subsea pod, communicates with the electronic board within
the downhole SCRAMS tool. The subsea SCRAMS card
has been implemented with Aker Solutions, VetcoGray,
and FMC.

IWIS Features
• Support for ROC™ family of downhole gauges
• Secure downloadable firmware allowing software
upgrade in the field
• Supplied with 6HP front panel that can be optionally
fitted by the customer

IWIS Benefits
• Enables downhole gauge system for a subsea completion
Subsea Interface Card
where the subsea control system is provided by any IWIS
compliant supplier

3-52 WellDynamics
 Subsea Interface Cards
VetcoGray Cameron FMC FMC Aker Solutions Aker Solutions
IWIS
Pod Pod Pod Pod Pod Pod

9670 - 6015
Halliburton
(standard)
WellDynamics 9670 - 6010 9670 - 6050 9670 - 6000 9670 - 6040 9550 - 6140 9670 - 6060
9670 - 6016
Part Number
(unit converting)
DHI204/
Customer DHI109/ DHI108/
– – – – P6000041999
Part Number 100016417 7104455
(FMC)
Standard Standard Standard Standard Standard Standard
Physical 3rd Generation
Eurocard Eurocard Eurocard Eurocard Eurocard Eurocard
Format Pod-Specific
100 × 160 mm 100 × 160 mm 100 × 160 mm 100 × 160 mm 100 × 160 mm 100 × 160 mm

Interface DIN41612 DIN41612 2x DIN41612 2x DIN41612 DIN41612 Hypertac® DIN41612

Connector male male male male male male male

Supply
24 VDC ±10% 24 VDC ±10% 24 VDC ±10% 24 VDC ± 5% 24 VDC ± 5% 48 VDC ± 5% 24 VDC ± 25%
Voltage

Maximum Power
8W 8W 8W 7.5W 8W 4W 9W
Consumption

Maximum On-Board
3W 3W 3W 2W 3W 2W 4W
Power Consumption

Operating
-20 to + 70°C -20 to + 70°C -20 to + 70°C -7.5 to + 70°C -25 to + 70°C -10 to + 50°C -20 to + 70°C
Temperature

Random 6g, 20-2000 Hz 6g, 20-2000 Hz 5g, 20-2000 Hz 5g, 20-2000 Hz 5g, 25-1000 Hz
Vibration 3-axis 3-axis 3-axis 3-axis 3-axis

6-axis, 30g 6-axis, 30g 6-axis, 30g 6-axis, 30g 6-axis, 30g
Shock
11ms, 1/2 sine 11ms, 1/2 sine 11ms, 1/2 sine 11ms, 1/2 sine 11ms, 1/2 sine

Host
Communications RS485 RS485 RS485 RS485 RS485 RS232 RS422
Hardware Interface

Host
Modbus® Modbus Modbus Modbus Modbus Modbus Transparent via
Communications
RTU RTU RTU RTU RTU RTU PPP
Protocol

Maximum Number of 5 (9670 - 6015)

5 5 4 5 2 5
Gauges at 30,000 ft 4 (9670 - 6016)

Hypertac is a registered trademark of Smiths Interconnect.

Modbus is a registered trademark of Schneider Automation, Inc.

WellDynamics 3-53
3-54 WellDynamics