Thermocouple Solutions Engineered for HPHT Oil & Gas Wells
When a well enters High Pressure, High Temperature (HPHT) territory, getting trustworthy downhole temperature data becomes mission critical for drilling efficiency, artificial lift reliability, and long-term well integrity. The industry typically classifies HPHT as ≥150 °C (300 °F) with pressure control equipment >10,000 psi; deepwater and ultradeep cases can push far beyond that, with reported downhole pressures >35,000 psi and temperatures ≈500 °F.
Thermocouples remain the workhorse sensor for this environment. Paired with rugged assemblies, they deliver fast response and survive intense vibration, pressure, and thermal cycling, exactly what the wellbore demands.
What “Right‑Fit” Downhole Thermocouple Wire Looks Like
Designing wire for HPHT realities means balancing electrical accuracy with mechanical and chemical survivability. Here’s how Pelican Wire approaches the construction details:
1) Calibration type matched to the job
- We also supply Types J, K, T, N & E when the application calls for them, across Thermocouple and extension grade builds.
2) Accuracy & stability you can audit
Your operating envelope and control strategy determine whether Standard or Special Limits of Error are appropriate. Our calibration practices follow ASTM E220/E230 and AMS 2750, with NIST traceability; Pelican Wire’s calibration capabilities are aligned with ISO/IEC 17025 lab guidelines.
3) Insulation/Jacket Built for Both Heat and Chemistry
- For HPHT zones and hot sections, vitreous silica and ceramic systems offer the temperature headroom, up to 1600 °F (871 °C) and 2200 °F (1204 °C) respectively.
- For cooler segments and long extensions to surface, fluoropolymers (e.g., PFA/FEP & P300) provide chemical resistance with continuous ratings to 260–300 °C.
- Constructions can be extruded, tape wrapped, served, or braided depending on bend radius, routing, and abrasion concerns.
4) Mechanical hardening for the load path
Downhole assemblies see shock, vibration, and cyclical strain. While the final pressure boundary often comes from probe sections and wellhead feedthroughs. Pelican Wire’s role is supplying the thermocouple and extension wires that mate with those systems, engineered for lay, twist, gauge, and sheath compatibility so your measurement chain stays coherent from hot zone to surface.
Where the Temperature Data Pays Off
- MWD/LWD & drilling – Managing bottom‑hole assembly (BHA) health and drilling parameters; temperature is often the limiting factor even when pressure is under control.
- Artificial lift (ESP/PCP) – Monitoring motor windings and intake/discharge temperature to optimize speed, avoid gas lock, and extend run life.
- Thermal EOR & SAGD – Multi‑point temperature tracking during steam injection and soak cycles to protect tubulars and improve sweep efficiency.
Permanent well surveillance & integrity – Thermocouples complement distributed fiberoptic temperature sensing (DTS) for long-term, high resolution thermal profiles and well diagnostics.
Why Oil & Gas Teams Specify Pelican Wire
- Breadth of thermocouple offerings (J, K, T, E, N) with custom constructions for HPHT service.
- High temperature product depth strengthened by our acquisition of a segment of the Watlow SERVRITE® high Temp thermocouple wire line; we manufacture to ASTM E230/E220 and AMS 2750 standards, with NIST traceability.
- Insulation systems that span fluoropolymers, glass, vitreous silica, and ceramic for the exact heat/chemistry envelope you face.
- Quality you can document: Traceable spools, certified calibrations, and a Quality system aligned with ISO/IEC 17025.
Proven Across Industries You Know
Beyond oil & gas, Pelican Wire supplies temperature critical wire to Aerospace, Autoclave/Sterilization, Automotive, Cryogenics, E-Textiles, Medical Devices, Radiant Flooring, Robotics, UAV, and Wind Energy. The array of industries served only adds to the breadth of experience that sharpens our materials, manufacturing, and testing discipline for every new downhole design.
Get a Downhole ready Wire Design Started NOW!
Every well is different. Send Pelican Wire your temperature window, expected pressure, fluid composition (H₂S/CO₂/brine), measurement depth, target accuracy (Standard vs. Special), conductor gauge, length, and routing constraints. Our Engineering team will translate that into a right‑sized thermocouple or extension wire construction, calibrated, documented, and ready to integrate with your HPHT assembly.
Don’t wait for drift or downtime to force a change. Start your thermocouple wire design with Pelican Wire today. Click Request a Quote below or contact our team at (239) 597-8555 & we’ll help you specify a build you can trust from the hottest zone to the surface readout.
PS: For a quick video introduction to Pelican Wire & our many Capabilities, Click Here.