No: 12OHS4552000

SAP: Universal
Date: 4-13-15
Basic Design and Maintenance Instructions
Revision: C

Halliburton ZoneGuard™ Short Packer

ATTENTION All Halliburton Completion Tools shall be repaired or redressed in accordance with established
procedures. In no case shall repairs or redress of Halliburton Completion Tools be attempted without
a copy of the applicable BDMI or operating manual, bill of materials, EDS, and assembly drawing.
This BDMI covers 12OHS4552380-B, 12OHS4552381-B, and 12OHS4552382-B.
If the information in this BDMI does not apply to your particular ZoneGuard Packer,
BDMIs for individual ZoneGuard Packers are located on HalWorld. If a BDMI is
needed and not available, one can be ordered by going to HalWorld BDMIs and
clicking on "Order BDMI's" at the top of the BDMI home page. Contact Engineering
there is any question regarding the proper BDMI.

Table of Contents
Design Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Issues and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Recommended Shop Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
In-Shop Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Prejob Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Checks for Proper Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
On-Site Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Field Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Plug for Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Running and Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Body Lock Ring/Internal Slip Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Body Lock System Functionality (How It Works). . . . . . . . . . . . . . . . . . . . . . . . . . 24
Body Lock Ring System Pre-Assembly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Thread Make-Up Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Copy is uncontrolled.
These instructions describe results from the use of Halliburton equipment, but such results are not guaranteed. Operation of equipment is subject to mechanical limitations and
Halliburton shall only be liable for merchandise and service as set forth in its general terms and contract.
© 2015 Halliburton

Page 1 of 28
Halliburton ZoneGuard™ Short Packer Design Overview

Design Overview
The Halliburton ZoneGuard™ Short Packer is a hydraulic set isolation
packer designed to be run and set in open hole or cased hole, horizontal or
vertical wellbores. This packer provides highly efficient, zonal isolation in
openhole applications, making it a cost-effective alternative to inflatables.
The setting system is protected from movement while running into the well
to prevent any pre-loading of the setting shear screws. The ZoneGuard
Short Packer has a pressure actuated setting system that can be adjusted for
surface indication when running multiple packers. This packer has no shear
release feature. However, the packer can be milled out.

The ZoneGuard isolation system is designed for running and setting in open
or cased hole. In open hole applications, sealing integrity will be dependent
on the condition of the borehole. Production control of water or gas can be
achieved in either horizontal or vertical wellbores. The use of centralizers
should be considered as appropriate in deviated/horizontal applications.
Any number of sections of the wellbore can be isolated by running and
setting tandem systems.

The ZoneGuard isolation system contains elastomers with slightly higher

expansion ratios to conform to limited openhole irregularities. If possible,
select a ZoneGuard packer having an OD within 1/2 in. of the borehole
diameter (1/4 in. maximum running clearance per side). In no event should
the running clearance be allowed to exceed 3/8 in. per side. The durable
design features a small OD to allow running and placement. A positive
internal lock is also included for a reliable, long-term pack-off. The system
is hydraulically set and may be used in tandem with other completion tools
as required.

Applications
• Zonal isolation in cased or openhole
• Gas or water shut-off
• Stimulation
• Production testing
• Formation fracture isolation
• Selective production
• Individual interval stimulation and cleanup
• Stage cementing jobs
• Horizontal drawdown control
• Lateral abandonment

12OHS4552000 Universal Revision: C Page 2 of 28

Halliburton ZoneGuard™ Short Packer Safety Issues and Warnings

Safety Issues and Warnings

Ensure that all Health, Safety, and Environment (HSE) requirements are
met before commencing the work. Maintain good housekeeping standards
in the work area at all times.

Personal Protective Equipment—Ensure that all required PPE (safety

glasses, gloves, steel-toed shoes, and hard hats, if required) is worn.
Hand Tools—All hand tools must be clean and in good working condition.
Hammers, chisels, and punches should not have mushroomed heads that
will chip when hit. Wrenches should have sharp hooks and heels and not
have bent handles. Ensure the tools are not greasy to avoid slipping that
may result in serious personal injury.
Hair must be styled in a manner to prevent exposure to the hazard of
entanglement or completely covered.
No Jewelry—bracelets, chains, earrings, necklaces, rings, wristwatches,
ornamental jewelry, etc.
Clothing—No improper clothing that may expose the individual to the risk
of entanglement. This may include ragged, torn, or loose fitting clothing.
No non-tear-away aprons, ties, scarves, hair ribbons, etc.
Heavy Objects—Do not lift heavy objects (over 35 lb) without using lifting
equipment or assistance from additional people. Ensure proper lifting
techniques are utilized, and get help if necessary. Use proper lifting
equipment such as slings, fork truck, crane, etc., when needed.
Ensure all lifting equipment such as slings, chains, overhead cranes, fork
trucks, etc., are in good working condition and working order.
Many of the test fixtures and accessories are bulky and can cause injury if
not properly handled. Follow proper lifting procedures and keep fingers out
of potential pinch points.
Lifting Equipment—When lifting equipment, pay special attention to
where slings are applied or the forks of a fork truck are placed. Slings and
forks should be spaced wide apart to ensure the equipment is stable and not
prone to tilting and risk dropping to the ground. The slings and/or forks
must not contact slips, exposed seals, sealing surfaces, or any components
that are shear pinned in place. Exposed collets and springs must be
protected and avoided. Never place hooks in threaded ends.
Take extra precautions when lifting long assemblies to ensure the setting
tool and the packer assembly are not damaged. Refer to Technology
Bulletin CPS109.

Pinch Points—When handling and assembling components, keep hands

and fingers away from thread connections and from between moving parts.
Special handling tools are sometimes needed to keep hands out of critical
areas. Some assemblies have moving internal components. Keep hands and
fingers clear of moving internal components.

12OHS4552000 Universal Revision: C Page 3 of 28

Halliburton ZoneGuard™ Short Packer Storage

Sharp Objects—The assembly has several components that can cut

through skin (i.e., slip’s sharp teeth, threaded components, etc.). Never rub
bare fingers across the threads or sharp edges. Wear gloves when handling
sharp components.
Chemicals— Be aware of chemicals used to clean equipment to ensure they
are not hazardous when breathed or otherwise absorbed. Any hazardous
chemicals must be identified and precautions taken to avoid personal
contact.
Spills— Spillage of any fluids must be cleaned immediately to prevent
slipping hazards.

High Pressure—High pressures may be utilized when performing pressure

tests. Pressure testing the assembly creates potential for projectiles if an
equipment failure occurs. Maintain test equipment in good working order.
Identify weak links and remove as much air as possible from the system.
Utilize test bays when possible. If no dedicated test area is available,
evacuate the area when testing occurs. Restrict the presence of nonessential
personnel from the testing area.

Storage
Halliburton’s Packer is a precisely built piece of equipment that contains
numerous seal surfaces, threads, shear pins, brittle components, and
elastomers. Before storing, inspect the packer for any obvious damage. It is
essential that the packer be protected from environmental elements that
could cause corrosion or degradation of these components during storage.

When the packer is packed for international shipping direct exposure to the
weather is avoided. However, packaging may become damaged during
inspections so this packing should not be relied upon for warehousing.
During extended storage, components may eventually react to the humidity
in the air.

The following procedures are recommended:

• Store the equipment indoors.

– The indoor environment should be air conditioned and/or heated to
prevent large temperature variations and to control the humidity.
– If indoor facilities are not available, the equipment should at least
be under a roofed shelter and not exposed to rain or precipitation.
• Inspect the equipment to ensure no corrosion or dirt has accumulated
well enough in advance of a completion that repairs or redress is
possible prior to the completion if necessary.
• If corrosion or dirt buildup is observed, clean the equipment thoroughly
and take action to prevent this buildup.

12OHS4552000 Universal Revision: C Page 4 of 28

Halliburton ZoneGuard™ Short Packer Recommended Shop Practices

• All metallic components should be protected with a light oil or suitable

corrosion inhibitor. This includes the mandrel bore. Sand control
packers are not painted to prevent paint chips from fouling the pack or
screen.
• The exposed elastomers should be wrapped in heavy paper to protect
against light, dirt, and mechanical damage.
• All exposed threads should be protected with suitable closed-ended
protectors at all times.
• Rotate the inventory to reduce the age of the inventory (first in; first
out). The oldest equipment should be used first before new equipment is
used.

Note Elastomers have a limited shelf life. Rotate inventory to use

elastomers before their shelf life expires. Ozone producing equipment such
as electric motors or lights should be a safe distance away from elastomers.

Packers sent out as backup packers should always be redressed upon return
and prior to being sent out on a subsequent job to avoid sticking due to
corrosion.

If the packer has been allowed to corrode, the packer should be

disassembled and redressed.

Recommended Shop Practices

• Take care where the wrench or vise is placed to avoid damage to sealing
surfaces.
• Do not deform thin sections of mandrels or box threads with an
improperly placed wrench or vise.
• Always support the free end of the packer with a shop stand when
placed in the vise.
• Always replace all elastomer components (o-rings, elements, and seals),
shear screws, shear pins, set screws, and Spirolox rings when redressing
a packer. These items are not reusable.
• Remove all shear pin and shear screw remnants.
• All shear screw and set screw thread holes should be cleaned with the
thread taps prior to reassembly.
• Use clear grease containing no solids liberally on all components during
assembly, unless noted otherwise. The grease eases assembly and
protects the internal components against corrosion during storage.
• All seal surfaces and seal components must be greased during assembly.
• All tubing threads, boxes, and pins should be cleaned by hand with a
wire brush and coated with an API thread compound.

Note Use suitable API thread compound on the mandrel threads.

12OHS4552000 Universal Revision: C Page 5 of 28

Halliburton ZoneGuard™ Short Packer In-Shop Procedures

In-Shop Procedures
When preparing for workshop assembly and testing, all equipment and
necessary equipment should be located and staged in one location.
Inspection of the equipment should be performed to ensure the assembly
process might be carried out smoothly without unnecessary interruptions.
The preparation activities should include but not be limited to the following
items:

• Confirm the specifications of the packer and other equipment are

consistent with the planned completion. This includes the thread
connections and casing size and weight.
• Caliper the OD of the packer and compare the measurement with the
value given in the Engineering Design Specifications (EDS).
• Drift the ID of all equipment with a suitable drift bar. Equipment with
honed bores such as sub-surface safety valves, landing nipples, and
sliding sleeves may require special drift bars.
• Check the packer for obvious damage such as broken/cracked
components, damaged rubber, mashed or galled threads, sheared
screws, broken control lines, etc.
• Determine the correct torque values required for all threads that will be
made up.
• Verify all test pressures and ensure the test fixtures and equipment will
safely achieve these pressures.
• Identify any special tools, fixtures, and consumable supplies such as
thread dope, lubricant, o-rings, seals, control-line connectors, etc., and
ensure they are available.
• It is recommended to install a pup joint to the bottom of the packer to
facilitate makeup at the well site if an extended tail pipe assembly is
used.

12OHS4552000 Universal Revision: C Page 6 of 28

Halliburton ZoneGuard™ Short Packer Prejob Planning

Prejob Planning
During the planning phase of the completion, numerous issues should be
addressed and information gathered.

Define operational parameters. Specify production requirements and

potential injection and/or stimulation scenarios. These aspects may dictate
minimum tubular dimensions and strengths. Potential future workover
aspects should also be defined at this stage.

Confirm completion requirements. A wellbore schematic should be

prepared showing depths, maximum ODs, minimum IDs, and lengths of all
completion components. Operating pressures and temperatures should be
identified. It is very important to clearly define all casing, liner, and tubing
weights as this will confirm drift diameters and potential string weights and
strengths.

Prepare a preliminary installation procedure. This will assist with

operational issues by establishing required installation sequences. This will
also identify the need for special fixtures and/or handling equipment.

Perform tubing movement analysis. This will ensure all desired

operational goals may be achieved. This analysis will also determine
stresses generated on the tubing as well as the completion equipment.
Higher strength metallurgy may be required for certain components.

Review specifications of all downhole components. This will ensure

critical dimensions, pressure ratings, and temperature ratings are compatible
with all aspects of the proposed completion procedures.

Confirm availability of required equipment. This should include

backups, spare parts, test fixtures, installation tools, retrieving tools,
handling equipment, etc.

12OHS4552000 Universal Revision: C Page 7 of 28

Halliburton ZoneGuard™ Short Packer Checks for Proper Operation

Checks for Proper Operation

• Caliper the tool OD to be sure that the packer is correctly dressed for
the casing weight in which it is to be set. Compare dimensions with
specification sheets.
• Check casing string details to check that if a composite string has been
used the packer as dressed can run through the smallest diameter and set
in the desired position. Compare to weight ranges in the specification
sheets.
• Run a drift of appropriate size through the ID of the tool to ensure it is
within specifications.
• Check that the rubber system installed is compatible with well
conditions.

On-Site Procedure
• Check the packer for any apparent damage due to shipping. Document
the OD, ID, length, part number, number and type of shear pins, serial
number, and any other pertinent information.
• Hold a pre-run meeting with the rig or wireline crew to discuss running
speed and other critical installation procedures.

Note Use suitable API thread compound on the mandrel threads.

12OHS4552000 Universal Revision: C Page 8 of 28

Halliburton ZoneGuard™ Short Packer Assembly Testing

Assembly Testing
WARNING Ensure all safety precautions are taken prior to beginning any pressure
testing. These precautions should include the erection of signs and barriers,
PA announcements, removal of non-essential personnel, and the use of
work permits. Review JSAs, and never test alone.

Note Use properly inhibited test fluids to avoid corrosion.

Test fluids should be drained and the tool should be dried as much as
practical after shop testing.

Use the appropriate test fixtures called out on the Engineering Design
Specifications and replace the brass shear screws with the steel test pins as
shown in the picture below. After assembly is complete the packer must be
internally pressure tested at 500 psi for 5 minutes without any leaks.
Release the test pressure and remove the test fixtures.

Test pins
81T15960

Test strap

Test pin installation

Note Halliburton recommends a minimum safety factor of 1.50 for

surface pressure tests. This includes all fixtures, pumps, lines, etc.

12OHS4552000 Universal Revision: C Page 9 of 28

Halliburton ZoneGuard™ Short Packer Field Testing

Field Testing
WARNING Ensure all safety precautions are taken prior to beginning any pressure
testing. These precautions should include the erection of signs and barriers,
PA announcements, removal of non-essential personnel, and the use of
work permits. Review JSAs, and never test alone.

Note Use properly inhibited test fluids to avoid corrosion.

Test fluids should be drained and the tool should be dried as much as
practical after shop testing.

Use the appropriate test fixtures called out on the Engineering Design
Specifications, the packer may be tested to the specified test pressure listed
in the Engineering Design Specifications.

A field camp pressure test must be completed prior to the ZoneGuard

Packers being RIH. It is required to remove the brass shear pins installed in
the packers coming from manufacturing and replace them with steel set
screws. The steel set screws will prevent the packer from pre-setting during
the pressure test operation. It is recommended to complete a field camp
pressure test exceeding the minimum setting pressure of the ZoneGuard
Packers prior to running in hole to ensure there will be no issues with the
internal o-rings during the setting procedure. Complete an internal pressure
test of the ZoneGuard Packers between 3,500psi and 5,000 psi, holding the
pressure for 5 minutes without any leaks. Calculate the lbs.-force that will
be applied to the steel test pins to ensure it does not exceed the test pin
ratings. See the following test pressure steel set screws required per
ZoneGuard Packer size and style. The required quantity must all be
installed into the packer during the pressure test.

Field Camp Internal Pressure Steel Test Pin Chart

ZoneGuard SR Style Packers
Size Steel Test Pin Qty Required Test Pin Rating (per 4 pins)
4-1/2" 101241046 4 75,000 lbs.-force
5-1/2" 63535 4 130,000 lbs.-force
6-5/8" 63535 4 130,000 lbs.-force
Notes: The quantity of steel test pins required per the chart must all be installed
during the pressure test. The steel test screws for the 4-1/2” packers are 7/8” in length
and will be larger that OD of the packer by approximately 1/2”. The 5-1/2" steel test
screws are 3/4" in length and will be larger than the OD of the packer by
approximately 1/4". These cap head steel test pins must be removed and brass shear
screws installed prior to sending to well location.

12OHS4552000 Universal Revision: C Page 10 of 28

Halliburton ZoneGuard™ Short Packer Plug for Tubing

Plug for Tubing

A means must be provided to plug the tubing string below the packer. A
catcher sub assembly that permits a ball to be pumped down and seals off
the tubing string can be used, or a landing nipple may be installed below the
packer in which a wireline-retrievable plug may be landed.

Note The plugging device must be removed after the packer is set.

Other tubing plugging devices such as retrievable plugs (Monolock® and

HE3®) or disappearing plugs (Mirage® and Anvil®) may offer significant
benefits in the large size applications that this packer is designed for.

Setting Pressure
Shear screws retain the packer in the run position. Application of hydraulic
setting pressure shears the screws and the packer sets. The quantity of shear
screws installed in a packer can be varied to change the value of the
required start-to-set pressure. This value will vary with the quantity of shear
screws installed and with variations in the actual shear values of the screws.

The start-to-set pressure P is equal to:

(Shear value per screw, lb) (Quantity of screws)

P=
(Piston area, sq. in.)

After the start-to-set pressure has been applied, the minimum setting
pressure must be applied prior to any attempts to pressure test or apply
overpull to the packer. In addition, annulus pressure should be applied while
holding the minimum setting pressure on the tubing string as per the
Engineering Design Specifications.

Note The minimum setting pressure listed in the Engineering Design

Specifications must be applied regardless of the start-to-set pressure.

12OHS4552000 Universal Revision: C Page 11 of 28

Halliburton ZoneGuard™ Short Packer Running and Setting Procedure

Running and Setting Procedure

CAUTION Do not apply torque across this assembly while making up or breaking out
the tubing thread. Grip on the end subs or mandrel directly to apply torque
or to hold backup.

Running speed is critical, especially in heavy or viscous fluid where excess

speed can result in swabbing off the packing element or in creating pressure
waves which could lead to creating a preset condition. As a guide it is
recommended to keep 95% of the string weight on the weight indicator or
the running speed should not be less than 30 seconds per joint (range II or
30 ft). Do not exceed this speed, particularly when running the packer in
the heaviest weight casing for the range for which the packer is dressed. A
run in the well with a junk basket and suitable sized gauge ring or a bit and
scraper is strongly recommended prior to running. The location of any tight
spots should be noted and the running speed for the packer through these
spots should be reduced.

1. Make up the packer into the tubing string and lower to the desired
setting depth.
2. Circulate a ball down to land in a catcher sub assembly or wireline plug
to allow the setting string to be pressurized from the surface to the
plugging device below the packer.
3. Apply pressure to the tubing string. The pressure enters the
cylinder/piston cavity through ports in the mandrel. The pressure forces
the piston downward shearing the setting shear screws, and compresses
the element stack. The internal slips engage the lock support and lock
the packer in the set position.

Note The packer is now completely set.

12OHS4552000 Universal Revision: C Page 12 of 28

Halliburton ZoneGuard™ Short Packer Disassembly Instructions

Disassembly Instructions
Refer to the Engineering Design Specifications, Bill of Material, and
Drawing.

WARNING Review the “Safety Issues and Warnings” on page 3 before proceeding with
the following steps.

Disassembly Notes
• Be sure all components are aligned to prevent galling of components.
• Take care of the location where the vise and wrenches are clamped. Do
not damage external seal surfaces. In addition, do not clamp on or
wrench on thin-walled components that may be damaged.
• Properly support long assemblies when placed in the vise. Use
adjustable stands to support the assemblies in a level condition.
• Properly support the end of assemblies when using wrenches to tighten
or loosen connections. Unsupported assemblies will stress the thread
connection and is likely to cause galling.
• Discard all o-rings, seals, or set screws.

1. Clean the outside of the assembly completely to remove any well debris
and chemicals.

WARNING Be sure to wear appropriate Personal Protective Equipment when cleaning.

Ensure the cleaning process does not cause environmental pollution.

2. Clean work area. Remove any components not related to this assembly.
3. Place the packer in the vise, gripping on the upper end on the
mandrel (2).

Note Unless necessary for repair, the coupling (1) does not need to be
removed from the mandrel (2).

4. Remove set screws (27) from the bottom sub (32).

5. Remove the bottom sub (32) from the mandrel (2).
6. Remove set screws (27) from the stop ring housing (28).
7. Holding a backup on the adapter (26), remove the stop ring
housing (28).
8. Remove the stop ring (29) from the mandrel (2).
9. Remove the adapter (26) from the lock-ring mandrel (20).
10. Holding a backup on the lock-ring housing (21) remove the shear
ring (25).

Note If the shear screws (24) have not been sheared, remove the shear
screws from the shear ring (25) before performing Step 10.

12OHS4552000 Universal Revision: C Page 13 of 28

Halliburton ZoneGuard™ Short Packer Disassembly Instructions

11. Remove the shear screw (24) remnants from the shear ring (25).

Note It is recommended to screw the shear screw remnants in towards the

ID instead of attempting to back them out. The damaged thread at the shear
plane usually prevents the remnants from backing out easily.

12. Place a back-up on the cylinder (19) and remove the lock-ring
housing (21). Once unthreaded, remove the lock-ring housing and
lock-ring mandrel (20) from the mandrel (2).
13. Using left-hand rotation, remove the lock-ring housing (21) and the
body-lock ring (22) from the lock-ring mandrel (20).
14. Remove the set screw (23) from the lock-ring housing (21).
15. Unthread the body lock ring (22) from the lock-ring housing (21).
16. Place a backup on the lower element retainer (8) and remove the
cylinder (19).

Note The chamber lock (15) will be free to fall out when the
cylinder (19) is removed.

17. Remove the chamber lock (15) from the piston (18).
18. Remove the piston (18) from the mandrel (2).
19. Remove the stop ring (14) from the mandrel (2).
20. Remove the snap ring (13) from the mandrel (2).

Note Do not over expand the snap ring (13).

21. Remove the lower element retainer (8) from the mandrel (2).
22. Remove and discard the elements (4, 5, 6 & 7).
23. Remove the upper element retainer (3) from the mandrel (2).
24. If necessary for repair, remove the coupling (1) from the mandrel (2).
25. Remove and discard the used o-rings.
26. Clean and inspect all the packer parts for wear and damage.

WARNING Be sure to wear appropriate Personal Protective Equipment when cleaning

the parts.

Pay close attention to threads for burrs that could cause damage upon
reassembling this valve.

Ensure the cleaning process does not cause environmental pollution.

Note Chase all set screw and shear screw threads with a tap to ensure the
threads are clean.

12OHS4552000 Universal Revision: C Page 14 of 28

Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Instructions
Refer to the Engineering Design Specifications, Bill of Material, and
Drawing.

WARNING Review the “Safety Issues and Warnings” on page 3 before proceeding with
the following steps.

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

1. Clean the work area. Remove any components from the work area that are not part of this assembly.
2. Collect all components that are to be assembled on a pallet or cart and verify that components match
part number and quantity on the Bill of Material.
3. Identify any special tools, fixtures, and consumable supplies such as thread dope, lubricant, o-rings,
seals, etc., and ensure they are available.
4. Place the coupling (1) in a vise.
5. Make up the mandrel (2) into the coupling (1) wrench tight. Torque to the value on the DSD.
Coupling (1) Mandrel (2)

6. Make up the upper element retainer (3) to the mandrel (2).

Upper Element Retainer (3) Mandrel (2)

7. Grease and install the end elements (4), outer elements (5), element spacers (6) and center
element (7) onto the mandrel (2).
Upper Element Retainer (3)
Element Stack (4, 5, 6, & 7)
Mandrel (2)

12OHS4552000 Universal Revision: C Page 15 of 28

Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

8. Grease and install o-rings (9 & 11) and back up rings (10 & 12) into and onto the element
retainer (8).
Note A scarf cut angle of 22° is recommended, as opposed to 45°, to reduce the axial displacement of
the free ends of the backup ring due to thermal expansion. Ensure the backup rings are installed
in the correct orientation with the curved surface next to the o-ring. There are two backup rings
per o-ring groove. When two backup rings are used, the scarf cuts should be 180° apart to
prevent the cumulative effects of two scarf cuts acting on the same o-ring cross-section.
.Ensure the o-rings are installed in the correct locations
22° (Approx.)
8 10 9 11 12

.000 Interference
Gap (Recommended)
.010
Proper Fit Improper Fit

Hoop Overlap

45°
22°
Axial Displacement
Top view of backup ring showing effect of the scarf cut angle on the displacement and overlap.

9. Install the lower element retainer (8) onto the mandrel and against the element package.

CAUTION Do not compress the element package.

Lower-Element Retainer (8) Mandrel (2)

10. Install the snap ring (13) onto the mandrel (2) below the lower element retainer (8).
Note Do not overexpand the snap ring (13).
Snap Ring (13)
Lower-Element Retainer (8)
Mandrel (2)

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Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

11. Install the stop ring (14) onto the mandrel (2), over the snap ring (13) and next to the lower element
retainer (8).
Lower-Element Retainer (8) Stop Ring (14)
Mandrel (2)

12. Grease and install o-rings (9 & 16) and back up rings (10 and 17) into and onto the piston (18).
Note See Step 8 for more information on properly installing back up rings.
Ensure the o-rings are installed in the correct locations.
13. Install the piston (18) over the mandrel (2) and next to the stop ring (14).
Stop Ring (14)
Lower-Element Retainer (8)
Piston (18) Mandrel (2)

14. Slide the cylinder (19) over the mandrel (2) leaving enough room to install the chamber locks (15).
Install the chamber locks onto the piston (18) (use grease to stick chamber locks in position until
covered by cylinder) and slide the cylinder over the lock chamber to hold it in place. Make up the
cylinder onto the lower-element retainer (8).
Note The chamber locks (15) are a matched set.
Do not compress the element stack.

Chamber
Lower Element Retainer (8) Locks (15) Cylinder (19)
Stop Ring (14)

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Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

15. Thread the body lock ring (22) using right-hand rotation into the lock ring housing (21) to the depth
listed in the Engineering Design Specifications and the Assembly Drawing (1.30 in.). Continue the
rotation until the wide slot in the body lock ring aligns with the set screw holes in the lock ring
housing. Install the set screw (23) into the internal slip housing and into the slot in the body lock
ring.
Note Ensure the body lock system has been checked according to “Body Lock Ring/Internal Slip
Installation Instructions” on page 24.
Ensure the set screws do not extend past the ID of the body lock ring. Do not apply Loctite to the
set screws at this time.
21 22 23
(1.30)

Incorrectly Matched Slip Correctly Matched Slip

16. Make up the shear ring (25) into the lock ring housing (21).
Lock Ring Housing (21) Shear Ring (25)

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Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

17. Install the lock ring housing (21) and associated parts over the lower end of the mandrel (20) and
align the shear holes in the shear ring (25) and the mandrel. Make sure that the start-to-set pin
threaded holes are aligned with the correct start-to-set pin spot face. Insert a test pin and verify the
alignment of all holes. Install the appropriate amount of shear screws (24) and tighten evenly. Ensure
the shear screws are below the OD of the shear ring.
Mandrel (20) Test Pin
Lock Ring Housing (21)
C
Shear Ring (25)

Install qty (2) of shear screw (item #24).

Place all remaining screws in original
bag. Place screws and original packaging
in cloth bag and attach to packer.

Section C-C

18. Remove set screw (23) from the lock ring housing (21). Apply loctite to the threads and reinstall the
screw into the lock ring housing until the screws bottoms out on the lock ring mandrel (20). Then
back the screw off 1/4 turn.
19. Slide the mandrel (20) and associated parts over the mandrel (2) and make up the lock ring
housing (21) into the cylinder (19).
Lock Ring Housing (21)
Cylinder (19)
Shear Ring (25)

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Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

20. Make up the adapter (26) onto the lock ring mandrel (20).
Cylinder (19)
Lock Ring Housing Adapter (26)

21. Install the stop ring (29) onto the mandrel (2).
Note Check the distance between the adapter (26) and the stop ring (29). The minimum allowed space
is .44 in. if the space between the adapter and the stop ring is less than this amount, contact
Engineering.
.44 Minimum
Adapter (26)
Stop Ring (29) Mandrel (2)

22. Holding a backup on the adapter (26) make up the stop ring housing (28) to the adapter. Install set
screws (27) into the stop ring housing and adapter.
Set Screw (27)
Adapter (26) Stop-Ring Housing (28)
Mandrel (2)

23. Grease and install o-rings (30) and backup rings (31) into the bottom sub (32).
Note See Step 8 for more information on properly installing back up rings.

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Halliburton ZoneGuard™ Short Packer Assembly Instructions

Assembly Procedure Initial

(Initial in the blocks to the right as the steps are completed)

24. Make up the bottom sub (32) to the mandrel (2) and install set screws (27).
Adapter (26) Stop-Ring Housing (28) Bottom Sub (32)
Mandrel (2)

25. Installation of all the components is vital for proper tool operation. Compare the completed assembly
to the Assembly Print.
26. Test the packer according to Engineering Design Specifications.

WARNING Ensure all safety precautions are taken prior to beginning any pressure
testing. These precautions should include the erection of signs and barriers,
PA announcements, removal of non-essential personnel, and the use of work
permits. Review JSAs, and never test alone.

Note Use properly inhibited test fluids to avoid corrosion.

27. Test fluids should be drained and the tool should be dried as much as practical after shop testing.

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Halliburton ZoneGuard™ Short Packer Assembly Drawing

Assembly Drawing

1
19

20

Torque per
DSD

B
2
21 Install the body lock ring (item #22) to
the reference depth as shown, then
22 rotate the body lock ring until the wide
slot in the ring is aligned with the set
23 screw holes in the housing (item #21).
Install set screw (item #23) until screw
3 (1.30) touches the mandrel (item #20) then
back off 1/4 turn.
C C

4 24

25

5 26

27
6
.44 min
7
28
29

27

Section A-A

8 30 31

9 10

11 12
32
13
14
15
16 17

Mark 18

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Halliburton ZoneGuard™ Short Packer Assembly Drawing

A A

Install qty (2) of shear screw (item #24).

Place all remaining screws in original
bag. Place screws and original packaging
in cloth bag and attach to packer.

Section C-C

Critical Assembly Inspection note:

1. Inspect lock ring system per ES-1-149.
Test pins
2. Inspection techniques for individual lock
ring system parts may be found in 81T15960
ES-MP-246.
3. If any variation is found contact engineering
for disposition. Test strap

Test pin installation

Detail B
Scale 4:1

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Halliburton ZoneGuard™ Short Packer Body Lock Ring/Internal Slip Installation Instructions

Body Lock Ring/Internal Slip Installation Instructions

Body Lock System Functionality (How It Works)

The body lock system consists of three main components: the mandrel,
housing, and the lock ring. The term "mandrel" as used here, refers to the
innermost component of the body lock system, and may or may not be the main
packer mandrel. In many cases it will represent the setting piston or other
component of the packer setting mechanism. The mandrel contains fine threads
that are used to limit and lock small increments of movement of the lock ring.
The housing is used to transfer load through its shallow thread angle which
pushes the lock ring into the fine mandrel thread and makes it clamp in place.
The housing is also used to move the lock ring by pushing the ring with its
steep angle, which keeps the lock ring from biting the mandrel thread (See
Figure 1). The lock ring serves as the transition piece that matches thread
forms, ratchets along the mandrel, and locks between the housing and mandrel,
preventing the packer from unsetting.

The primary purpose of the body lock system is to keep the packer in the set
position and transfer high loads through the packer. The body lock system is an
extremely efficient system designed to transfer high loads without crushing the
mandrel or expanding the housing. In most packer designs, all or some of the
loads, caused either by applied pressure or tubing forces, must pass through the
body lock system. To work properly, the housing has to be allowed to move
relative to the mandrel as illustrated in Figure 1. By design, the lock ring is
allowed to ratchet over the OD threads of the mandrel in one direction during
the setting process.

Housing
Mandrel
Body Lock Ring

Direction During Set

Figure 1:
Movement of Housing/Body Lock Ring Relative to the Mandrel While
Setting the Packer

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Halliburton ZoneGuard™ Short Packer Body Lock System Functionality (How It Works)

The orientation of the thread profiles of the housing, lock ring, and mandrel
prevents movement in the opposite direction and clamps the lock ring onto
the mandrel. The orientation of the thread profiles is critical to body lock
system performance (See Figure 2).

Housing

Direction During Loading

Load Direction

Body Lock Ring

Load Direction

Mandrel

Figure 2:
Load Direction of the Housing onto the Body Lock Ring and Mandrel
While the Packer is Set and During Loading

A key point of verification prior to assembly is the thread direction and

profile of each of the four threads that make up the body lock ring system. If
any threads on any of the three components are machined backwards or in
the wrong direction (i.e. a left-hand thread is cut instead of a right-hand
thread), the mating threads will cross, preventing the system from working
properly. The body lock system components must also be assembled in the
proper direction. Failure to properly machine or assemble the body lock
system component can result in a packer failure. Figure 3 illustrates the
mismatch between the ID threads of body lock ring and the OD threads of
the mandrel. This configuration could result from the OD threads of the
mandrel or the ID threads of the body lock ring being manufactured in the
wrong direction. This mismatch could also result from the ID threads of the
housing being machined in the wrong direction, allowing the body lock ring

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Halliburton ZoneGuard™ Short Packer Body Lock System Functionality (How It Works)

to be installed backwards as illustrated in Figure 4. Packer assembly

drawings have exploded views of the body lock system as shown in Figure
4 to aid the assembler in verifying the orientation of associated components.

Note If the thread profiles of any three components of the body lock
system are manufactured in the wrong direction, it could still be possible to
assemble the components onto the packer, but the packer will not function
properly.

Body Lock RIng

Mismatched Thread

Mandrel
Drawing Is For Reference Only

Figure 3:
Mismatch Thread Profiles

Drawing Is For Reference Only

Figure 4:
Correctly and Incorrectly Matched Body Lock Ring Systems

While each component is carefully inspected during the manufacturing

process according to engineering specifications, the following pre-assembly
checks are designed to confirm that each of the system components was
manufactured correctly, is assembled correctly, and will function as
intended.

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Halliburton ZoneGuard™ Short Packer Body Lock Ring System Pre-Assembly Checks

Body Lock Ring System Pre-Assembly Checks

Assembly of the internal slip is a simple procedure but is critical to the
success of the packer function. During packer assembly, the following
checks should be made to be sure that the slips are assembled properly.
Checks will also be made to ensure the internal slip/lock ring, internal
slip/lock ring housing, and mandrel thread forms have been machined
correctly.

1. Lay out the body lock ring system, including the mandrel, body lock
ring, and housing, oriented in the correct direction. Using the packer
assembly drawing, identify the direction of relative movement relative
to the setting motion of the packer.
2. Check to make sure that the tooth profile in the housing is oriented in
the proper direction by referring to Figure 1.
3. Check to make sure that the tooth profile on the outside of the lock ring
matches the tooth profile of the inside of the housing by referring to
Figure 1. The lock ring thread form is a non-symmetrical thread profile
that must be matched in the correct direction. Since the lock ring is a
c-ring, it is possible for it to be assembled incorrectly by being
collapsed and forced into the housing backward. If the lock ring has
been marked UP on one end, ensure that the mark UP after installation
is on the end closest to the top sub of the packer and at the same time
the tooth profile is correct.
4. Thread the lock ring into the housing to check the fit. This ensures that
both threads are of the same profile and threaded in the same direction.
The lock ring should easily screw into the housing by hand (loose fit);
however, all threads should be engaged. The loose fit at this point is
because the lock ring is not yet installed on the mandrel. Remove the
lock ring from the housing, as it will be required to check the fit with
the mandrel.
5. Check to make sure that the tooth profile on the mandrel is oriented in
the proper direction by referring to Figure 1.
6. Check to make sure that the tooth profile on the inside of the lock ring
matches that of the mandrel by referring to Figure 1. The lock ring
thread form is a non-symmetrical thread profile that must be matched in
the correct direction. Since the lock ring is a C-ring, it is possible for it
to be assembled incorrectly by being forced onto the mandrel backward.
If the lock ring has been marked UP on one end, ensure that the mark
UP after installation is on the end closest to the top sub of the packer
and at the same time the tooth profile is correct.
7. Install the lock ring onto the mandrel and check the fit. The lock ring
should be an interference fit when installed on the mandrel. Check that
all threads are fully engaged. This ensures that both threads are of the
same profile and threaded in the same direction.
8. If the fit of the individual thread profiles are correct, check the fit and
function of the entire body lock system. Use caution not to vise on any
threaded or sealing surface. Ensure that the components are clean and
free from burrs. Use only a very light coat of clear lubricant containing

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Halliburton ZoneGuard™ Short Packer Thread Make-Up Definitions

no solids on this system (do NOT use pipe compound). Install the
lockring and housing into the starting (run) position on the mandrel.
Make sure that the housing and lock ring will move with light
application of force for several inches in the setting direction, as
illustrated in Figure 1. Make sure that the housing and lock ring will not
move in the opposite direction by tapping with a hammer and block of
wood, as illustrated in Figure 2.
9. Remove the housing and lock ring from the mandrel.

Thread Make-Up Definitions

Hand Tight/Hand Tight Only

When Hand Tight or Hand Tight Only is called out in an Engineering
Design Specification or on an Assembly Drawing, the thread connection
between the appropriate components should be assembled only by hand.
The geometry or size of the components may require the use of a wrench for
gripping; however, no additional leverage should be applied when using a
wrench. This ensures that the connection can be broken and made up again
at a later date as required by the design intent.

Wrench Tight/Tight/Make Up Tight

When Wrench Tight, Tight, or Make Up Tight is called out in an
Engineering Design Specification or on an Assembly Drawing, the thread
connection between the appropriate components should be assembled with
the appropriate wrench needed to make up the thread connection. Usually
this would be a 24- to 48-in. wrench. The assembler is expected to safely
apply as much force as possible to the thread connection without any
additional power makeup. This process generally applies between 400 to
600 ft-lb of torque.

Torque Threads
When Torque Threads is called out in an Engineering Design Specification
or on an Assembly Drawing, the thread connection between the appropriate
components should be assembled wrench tight and then tightened to a value
listed or required by engineering. This is normally a "power makeup"
applied by using a torque machine that is capable of measuring the amount
of torque applied. If a torque machine is not available or applicable, the
required amount of torque can be applied using the appropriate wrench in
combination with a dynamometer gauge.

12OHS4552000 Universal Revision: C Page 28 of 28