Downhole Pressure Transmitters for Oil and Gas: Why the HI5000 Survives Extreme HPHT Wells

High-pressure, high-temperature wells are among the harshest environments in the oil and gas industry. Pressures can exceed 2,000 bar, temperatures can approach 200°C, and corrosive media and vibration are part of everyday operation. In these conditions, standard instrumentation quickly fails, and accurate pressure data becomes difficult to obtain. The HI5000 downhole pressure transmitter gives operators a reliable option for long-term monitoring in some of the world’s most demanding HPHT wells.

HI5000 downhole pressure transmitter for extreme HPHT conditions

Oil and gas operators rely on accurate wellbore pressure data to keep wells under control, optimise production and protect expensive downhole tools. Loss of signal or drifting measurements can compromise safety, reduce output and increase operational costs. A key challenge is finding instrumentation that can live in the well for extended periods without drifting out of specification or failing mechanically.

The HI5000 has been engineered specifically for harsh HPHT environments. With standard pressure ranges from 0–400 bar up to 0–2,000 bar, it can be matched to a wide variety of reservoirs and completion designs. Its high temperature rating of up to 200°C allows it to operate reliably in deeper, hotter wells where conventional sensors cannot survive. This makes it suitable for demanding oil and gas environments as well as emerging geothermal applications where both pressure and temperature are pushed to extremes.

NACE certified materials ensure compatibility with sour and corrosive media, protecting the sensor from hydrogen sulphide, carbon dioxide and other aggressive components often present in reservoir fluids. For operators, this means fewer failures caused by stress corrosion cracking and a longer, more predictable working life.

Silicon-on-Sapphire: the heart of the HI5000 downhole pressure transmitter

At the core of the HI5000 is an advanced Silicon-on-Sapphire sensing element. A piezoresistive silicon strain gauge circuit is epitaxially grown onto a sapphire diaphragm, creating a single crystalline structure. This sapphire element is then molecularly bonded to a titanium alloy sub-diaphragm, combining the mechanical strength and corrosion resistance of titanium with the thermal stability of sapphire.

This construction delivers several important performance benefits. The sensor exhibits virtually no hysteresis and excellent long-term stability over wide temperature ranges, which is vital in HPHT wells where conditions can fluctuate significantly. Silicon-on-Sapphire technology also offers very low drift over time, helping to maintain calibration and reducing the need for frequent intervention or recalibration at the surface.

Because the sensor is designed to withstand high shock and vibration inputs, it is well suited to harsh downhole environments where mechanical shock from drilling or production operations can easily damage more fragile devices. For operators, this robustness translates into more reliable data and fewer interruptions to well operations.

Compact downhole pressure transmitter design for space-limited tools

Downhole tools are often packed with electronics, valves and mechanical components, all within a very limited envelope. Space is at a premium, and every millimetre matters. The HI5000 addresses this constraint with a highly compact design, featuring a maximum length of just 57 mm. This allows tool designers to integrate high-performance pressure measurement into tight spaces without sacrificing other critical functionality.

The all-welded and sealed construction further enhances survivability in harsh and corrosive environments. There are no soft seals or mechanical joints that can degrade under temperature and pressure cycling, reducing potential leak paths and improving overall integrity. This is especially important where the instrument is deployed in locations that are difficult or impossible to service once the well is completed.

For drilling contractors and service companies, selecting a downhole pressure transmitter that can survive repeated thermal cycles and mechanical shocks is essential to avoid costly fishing jobs and tool failures. The compact, rugged construction of the HI5000 helps mitigate these risks while still delivering high-quality pressure data.

Matching performance to demanding oil and gas applications

The HI5000 is available in a range of standard pressure spans from 0–400 bar through 0–600, 0–1,000 and 0–1,500 bar up to 0–2,000 bar. This flexibility makes it suitable for a broad cross-section of applications, from monitoring pressure in upper completion components to deeper, high-pressure zones in challenging reservoirs.

By combining high temperature capability, very high pressure ratings and excellent corrosion resistance, the HI5000 can be deployed in both conventional and unconventional wells, including sour fields and offshore developments. Its stability and accuracy support better reservoir characterisation, production optimisation and pressure build-up analysis, giving operators a clearer picture of well behaviour over time.

Because the sensing technology maintains its performance over the long term, data from the HI5000 can be relied upon for critical decision-making, whether that is adjusting choke settings, planning stimulation treatments or deciding when to intervene in a well.

Choosing ESI Technology as your downhole partner

Developing instrumentation that survives HPHT wells requires deep understanding of materials, sensing technologies and the realities of field operations. ESI Technology designs and manufactures pressure measurement solutions in-house, drawing on decades of experience supplying demanding oil and gas applications.

By working closely with customers, ESI can tailor pressure ranges, mechanical interfaces and electrical outputs to suit specific downhole tools and operating conditions. The aim is not just to provide a device that meets a specification on paper, but to deliver a measurement solution that performs reliably for the full life of the well.

For operators and service companies looking to reduce non-productive time, improve safety and gain better insight into well performance, the HI5000 downhole pressure transmitter offers a proven, robust option. By choosing the HI5000 downhole pressure transmitter, oil and gas businesses can equip their HPHT wells with a compact, stable and corrosion-resistant pressure measurement solution that is designed to endure where many instruments fail.