ForgeFX will design, prototype, fabricate, and integrate tactile operator controls for Halliburton’s existing HWO training simulator. The system will preserve the current virtual-only experience while adding a physical-controls mode for higher-fidelity operator practice and assessment.
Proposal Due19 August 2026
Two ModesVirtual-only and physical controls
Two StationsJack operator and assistant operator
Pricing TBDAfter option and control inventory
01
Scope Definition
This is a new controls platform, not a reverse-engineering engagement for the obsolete Saudi-based simulator. The legacy equipment may inform layout and training needs, but ForgeFX will own the new design, integration logic, documentation, and build files created under the engagement.
Recommended baseline: begin with modular, 3D-printed jack-operator and assistant-operator control bases. Validate ergonomics, control selection, connectivity, and simulator behavior before considering a full furniture-style console or metal-cast enclosure.
02
Configuration Options
Halliburton asked for options that let leadership compare speed, cost, and training fidelity. Both options use the same core simulator-integration architecture.
Recommended Base Scope
Modular Control Bases
Portable tabletop or stand-mounted units centered on the essential jack-operator and assistant-operator controls.
One or two physical bases, subject to SME confirmation
3D-printed enclosure for rapid iteration
Generic enough to support SafeGrip and conventional HWO configurations
Nonessential controls may remain virtual or be remapped to available hardware
Designed for repair, replacement, and future module additions
Alternate / Additive Option
Full Training Console
A larger integrated station modeled after Halliburton’s existing coiled-tubing training setup, with operator controls, displays, cable management, and instructor-facing presentation.
Furniture-style operator station rather than portable bases
Integrated monitor or projector output in addition to VR
Potentially combines jack and assistant functions into one station
Higher fabrication, shipping, installation, and support effort
Requires complete manuals, dimensions, control inventories, and Halliburton SME review
03
Workstreams and Deliverables
The engagement is structured as a gated hardware-and-software program. Each gate produces reviewable evidence before the next investment is committed.
01
Discovery and Control Inventory
Run working sessions with Halliburton HWO SMEs to identify essential controls, roles, operating modes, ergonomics, and display needs. Compare SafeGrip, conventional HWO, the legacy training boxes, and at least one additional console example.
Approved control inventory and priority map
Jack-operator and assistant-operator responsibility matrix
Reference image, manual, dimension, and connector register
Decision record for one station versus two stations
02
System Architecture and Industrial Design
Define the physical enclosure, electronics, input devices, communications path, power, PC connection, external-display behavior, and simulator integration boundary.
Control-layout drawings and ergonomic review model
Electronics and connectivity architecture
Bill of materials with make/buy recommendations
Serviceability, modularity, and replacement strategy
03
Prototype Fabrication
Build functional 3D-printed prototypes for the selected control configuration. Use production-intent switches, levers, throttles, and connectors where practical, with temporary components clearly identified.
Functional prototype hardware
Enclosure and mounting files
Wiring, labeling, and assembly documentation
Bench-test results for every physical input
04
Simulator Integration
Connect physical inputs to the existing HWO simulator. Preserve the current virtual-only mode and add an RWC mode that loads the correct virtual control representation and maps hardware actions to existing simulator logic.
Hardware input abstraction and calibration layer
Physical-to-virtual control mapping
Virtual gauges and readouts in the simulator software
VR headset and PC/external-display operation
Configuration support for SafeGrip and conventional layouts where approved
05
Validation and Pilot Handoff
Validate the integrated system with Halliburton SMEs using representative HWO procedures. Resolve hardware, mapping, latency, ergonomics, and training-fidelity issues before pilot acceptance.
Factory acceptance test and issue log
Halliburton SME validation sessions
Operator and administrator quick-start guides
Source files, build files, schematics, and maintenance documentation
Pilot unit handoff and remote support window
06
Production Replication — Optional
After the pilot is accepted, quote additional units, hardened enclosures, metal fabrication, shipping cases, installation, spare parts, and support separately. Replication quantities are not part of the base scope.
04
Acceptance Criteria
The pilot is accepted when the agreed control configuration is proven as a complete training input system, not merely as fabricated hardware.
Hardware
Every approved control produces the correct stable input.
Enclosures, mounts, labels, and connectors match approved drawings.
The prototype withstands the agreed pilot-use test cycle without functional failure.
Calibration and component replacement can be performed from supplied documentation.
Simulator
Physical actions drive the intended HWO simulator functions with acceptable latency.
Virtual-only mode remains operational and unchanged except where explicitly approved.
RWC mode presents the approved virtual console and software gauges.
The instructor can observe the training view on the approved external display path.
Training Fidelity
Halliburton SMEs confirm that the essential jack and assistant operator tasks are represented.
SafeGrip and conventional differences are handled as approved during discovery.
Nonessential or deferred controls are clearly identified and do not block the selected training workflow.
Handoff
ForgeFX delivers the approved source, fabrication, wiring, configuration, and maintenance files.
Known temporary components, dependencies, and replication constraints are documented.
Open issues are resolved or accepted in writing before pilot closeout.
05
Halliburton Inputs and Responsibilities
Schedule and pricing depend on timely access to the operating knowledge and source material that define the control system.
Required Before Design Freeze
Named HWO SMEs for jack-operator and assistant-operator workflows
Control lists, labels, ranges, detents, spring behavior, and operating priorities
Photos, video, manuals, dimensions, wiring information, and connector details for available reference consoles
A second console example to establish what should remain generic across HWO configurations
Decision on modular bases versus full console, one station versus two, and required external displays
Required During Validation
Timely review of layouts, prototypes, and simulator mappings
Access to representative HWO procedures and training scenarios
Approval of any substitutions for unavailable or obsolete controls
IT and facility requirements for PCs, displays, power, networking, installation, and deployment
Shipping destination, import constraints, and pilot support expectations
06
Boundaries and Exclusions
These items are outside the base scope unless specifically added after discovery.
Excluded or Deferred
Boundary
Commercial Treatment
Reverse engineering the obsolete Saudi hardware
No reliable documentation, access, or development-unit availability exists. The hardware is reference material only.
Separate feasibility effort if Halliburton later supplies a working unit.
Full HWO simulator expansion
New lessons, offshore environment, localization, scenario builder, and unrelated Cementing Services work are sibling scopes.
Separate opportunity and pricing.
Production quantities
The base scope covers discovery, prototype, integration, and one accepted pilot configuration.
Quoted after pilot acceptance and quantity forecast.
Metal casting or production tooling
3D-printed modular enclosures are the baseline through validation.
Optional production-hardening phase.
Travel to Saudi Arabia
Remote review is the baseline. Travel does not replace the need for a development unit during integration.
Preapproved travel and expenses quoted separately.
Halliburton network, MDM, or headset fleet changes
ArborXR, Intune, device procurement, and global fleet support are not required to prove RWC integration.
Separate support or deployment scope.
07
Open Decisions Before Final Pricing
The internal record supports the direction, but not a defensible fixed price or delivery date yet.
Halliburton Decisions
Modular bases, full console, or a priced comparison of both?
One combined station or separate jack and assistant stations?
Which controls are essential, optional, or virtual-only?
Must the pilot support both SafeGrip and conventional HWO at launch?
Is a headset sufficient, or is an external monitor/projector mandatory?
ForgeFX Estimating Inputs
Dave’s hardware-fabrication feasibility and component review
Approved control count and source availability
Electronics, enclosure, PC, display, and mounting requirements
Prototype durability target and production quantity forecast
Halliburton review cadence, pilot location, and acceptance test duration
08
Internal Research Basis
This scope was synthesized from live ForgeFX internal systems and the exact opportunity record. External web research was intentionally not used because the request specified internal deep research.
Fireflies: Halliburton Cementing Services Touchpoint, 5 August 2026 — two-base cost-control concept, generic versus SafeGrip controls, full-console alternative, external display needs, and request to price both options.
ForgeBase observations 17362–17365 and 17472 — conventional versus SafeGrip differences, workover BOP simplification, reusable HWO assets, and related HWO requirements.
ForgeSales maintenance evidence — duplicate-opportunity merge history and missing cost-table status.
Confidence and caveats
High confidence: the customer wants a new Halliburton-owned physical control system integrated with the existing HWO simulator; the legacy Saudi equipment is undocumented and unavailable; modular 3D-printed prototypes are the preferred starting point; both virtual-only and physical-controls modes should remain available.
Medium confidence: the exact station count, control inventory, external-display requirement, SafeGrip/conventional launch coverage, and full-console option remain open pending Halliburton SME and ForgeFX hardware review.
Not established: fixed price, detailed schedule, production quantity, durability specification, pilot location, or final acceptance-test duration.
