HPC® Coating

Get “high” heat protection that surpasses conventional insulation with HPC® and HPC®-HT Coating. HPC® (Hot Pipe Coating) is a ceramic based, water-borne insulating coating designed to insulate in high temperature situations from 100° to 600°C. Use HPC® as an insulation to block heat loss, save energy, reduce maintenance, stop CUI (Corrosion Under Insulation), reduce landfill and for employee protection.


HPC Technical Data Sheet | Application | Safety Data Sheet (pdf)HPC HT SDS (pdf)HPC BrochureSPI Coatings


Superior Products International II Inc. Certified Coating

Maximum energy efficiency with a high temperature coating designed to insulate every surface

  • Replaces wraps and jacketing
  • Eliminates CUI
  • Easy to repair
  • Easy to maintain
  • Save energy
  • Water based and safe application
  • Protects personnel
  • No shut down required

HPC® applied while operating up to 260°C
HPC®-HT applied while operating up to 600°C

In today’s age of increasing energy demands, industries need innovative, high-heat solutions that will stand the test of time and delivery proven efficiency. The performance capabilities of HPC® / HPC® – HT Coating are why so many industries are choosing to switch to reduce energy demands and costs, reduce maintenance costs and reduce the risks of CUI.

When we designed the HPC® coatings, our goal was to address the concerns of insulation, energy savings, CUI and personnel protection, without shutting down equipment (and costing millions of dollars in the process). With HPC®, and now HPC®-HT, we have done just that!

Our aim was to produce measurable insulation performance in the field. HPC® and HPC® – HT are insulators that cover every centimetre, every surface including elbows and valves etc. to give 100% coverage for optimum insulative benefits. Many coatings insulate under 160°C, but with the HPC® and HPC® – HT, we take insulation from 100° to 600°C, and can apply while operating, with measurable, immediate results.

HPC® / HPC® – HT Coating were designed with lightweight, low-density ceramics developed in cooperation with NASA in the early 1990s. These unique materials give HPC® / HPC® – HT Coating the ability to reduce heat loss in a variety of industries that depend on high-heat efficiency. Many industries that benefit from HPC® / HPC® – HT include:

  • Energy
  • Mining
  • Aluminum
  • Bitumen
  • Pulp and Paper
  • Refining
  • Iron and Steel
  • Gas

HPC® Coating provides a “true insulation benefit” by holding the heat inside of the coated vessel and increasing the internal temperature/pressure if the energy source is not changed. Energy costs can be saved by reducing the energy requirement to maintain the original temperature or the manufacturing process can be improved by increasing the internal temperature of the vessel to achieve a more efficient and effective process.

HPC® does not degrade when exposed to environmental factors and maintains a constant level of performance throughout the lifespan of the coating/project – no decrease in effectiveness or efficiency. For additional protection a top coat of Enamo Grip, Super Therm, Rust Grip or Moist Metal Grip will extend the life of HPC®.

HPC® – single component water-based coating designed to insulate hot pipes or surfaces that load up to 260°C. The coating is not a reflective coating, but works to block the loading of higher heats and to resist the transfer of heat through the coating to the cooler side.

For industries that depend on optimum heating systems, HPC® / HPC®-HT Coating presents an innovative and efficient solution. HPC® / HPC®-HT Coating are formulated to prevent the loss of conductive and convective heat from pipe and vessel surfaces.

This capability maintains the overall heat of any fluid or gas within a pipe or vessel and allows the process to operate more efficiently. HPC® / HPC®-HT Coating will hold heat in a “transmission pipe” for longer distances than traditional insulation systems and will effectively maintain interior temperatures and reduce emissions for personnel protection.

Traditional Pipe Insulation

Traditional hot pipe insulation presents numerous inefficiencies and only slows the conductive heat transfer process because it contains small pockets of air. With HPC® / HPC® – HT Coating, heat loss is controlled by the light weight, low-density ceramics which results in more heat being held on the surface and increased temperature/pressure inside the pipe or vessel.

Traditional pipe insulation continually suffers from costly maintenance in large industrial piping systems. By absorbing air and moisture, traditional pipe insulation systems deteriorate rapidly, lose insulation performance, and cause CUI. In addition, the inability of traditional pipe insulation to cover and seal the valves, joints and elbows of various systems also creates gaps in protection for industries that depend on high heat efficiency.

Real Cost of CUI incidents

An example of this was a 2008 pipe failure at a Dow Chemical plant. Although the facility had an excellent track record of inspection, maintenance and safety standards, the high-pressure pipe system was constructed from aging materials. Their inspection failed to identify corrosion on a 30-year-old pipe. When the pipe failed, it exploded with such force that it buckled in two separate places. Fortunately the buckling happened to seal the pipe, preventing further damage until the system could be shut down and averting what could have been a disastrous situation for the plant. The total loss of the plant was $18.67 million by the incident which included loss of work days of 64 days. See more >


Photo of the crease in Dow pipe self-sealing the leak

Photo of the Dow pipe once removed

One instance of corrosion developing into more serious problems occurred at the Alaska drill site in the mid 1980’s. A hot gas/oil pipeline that carried gas from a flow station failed because 85% of the pipe’s wall had corroded away, the result of saturated thermal insulation.

In another case, severe corrosion occurred under polyurethane (PU) insulation on a hot tank. The insulation contained halogens from the fire retardant that had been applied to it. Water had combined with the halogens to create an environment of pH 1 accelerating the corrosion process. Source

CUI

The current talk of using “super hydrophobic” resins to impregnate existing materials only reduces the air space, which is the main insulation medium used. Reducing moisture is a plus. Any dry material is a better insulator than any wet material (example: if a screen is replacing jacketing, the screen conducts heat). Adding structure can reduce the insulation effect. At the end of the day, it’s simple – and proven: HPC® and HPC® – HT effectively eliminate CUI without adding structure, while blocking humidity and air.

Personnel Protection

Our HPC® Product Line addresses personnel safety issues by using two formulas for differing levels of temperature exposure, both of which are water-based and loaded with specific ceramic compounds (chosen from thousands of compounds that were evaluated over a 30-year period) that block “heat load” and transfer (HPC®-HT part A has some solvent, but when mixed with part B, it is fully water based). These compounds are then blended into unique resin systems to carry the ceramics onto surfaces and hold them together in a mesh-like structure, without becoming a conduit for heat.

You need to cover all four points of concern: Insulation, CUI, Personnel Protection and Energy Savings. Why would you only settle for one point at a time, with 3 different products? Instead, address the issues with specific products designed for what you need. Major customers have already used the HPC® product technologies in the field for years. They work. They’re proven!

HPC® Coating being applied at Gazprom (Russia’s largest LPG Energy supplier to Europe) and shows a 550°C hot pipe insulated down to less than 40°C in just minutes…all without a shutdown or hot permit. Manufactured by Superior Products International (SPI), Hot Pipe Coating (HPC) is available from NEOtech Coatings Australia.

This insulation method is much different than the traditional “wrap” insulation materials that only slow down the loss of heat (known as an R-rating or “heat transfer”). The eight ceramic compounds create a barrier to catch and hold heat on the surface of the unit, e.g. pipe, furnace surface, boiler, etc.

Unlike wraps that use air as the insulation component, the ceramic compounds in HPC® resist absorbing heat trying to come off the surface to escape. This traps and holds the heat onto the surface for more effective insulation performance.

HPC® test

A test on a heating pipe showing the powerful properties of ceramic insulation technology. Part of the pipe is painted with our Superior Products ceramic coating to show the comparison of the thin insulative film. Footage shows pipe reducing from 232°C to 35°C during application.

Additional benefits of HPC® Coating include:

Easy to Apply: Apply directly to hot pipes while operating. Spray with hopper guy or Graco 1500 TexSpray. Apply thin coats first, and after surface reduces heat level, thicker coats can be applied.

Increased Insulation: Additional coats immediately reduce surface temperature and loss of heat. 25mm over a 232°C pipe allowed someone to touch the surface safely at 60°C.*

Long Lasting: Does not absorb humidity or lose insulation value with overcoat of Super Therm®.

Safe: Non-flammable and non-toxic.

Coverage: Can be sprayed to fit over any configuration or shape.

Game changer for underground pipe insulation

SPI Coatings in cooperation with the largest interstate pipeline operator in the U.S. has developed a ground-breaking below grade insulative coating system. The new solution consists of an acrylic based insulative coating applied over a fusion bonded epoxy, wrapped in proprietary polyester mesh for structural strength, then top coated with a marine grade epoxy to seal the entire surface.

Conventional below grade insulation materials suffer from cathodic shielding. Laboratory and field testing proves HPC + Moist Metal Grip coating system does not cause cathodic shielding. SPI Coatings below grade insulative coating system is now a proven alternative to conventional jacket insulation, providing superior insulation and corrosion protection. This coating system can also be shop applied, making it a game changer for both below and above ground piping. Read more >

ROCKWOOL/FIBERGLASS WITH METAL JACKETHPC® COATING
INSTALLATION
Must shut down operation to installHPC® COATING is installed without a shutdown
INSULATION EFFECTIVENESS
Deteriorates rapidly and loses insulating value when moisture is present plus elbows & valves can not be wrapped effectively so heat losses are significant in these areasNon-Deteriorating and does not lose insulating value when moisture is present plus can be sprayed on elbows and valves reducing the significant heat losses through these areas
CRACK DETECTION
When a pipe cracks, the entire Jacket and RockWool or Fiberglass must be removed and repaired which requires downtimeWhen a pipe cracks, it can be inspected directly on the spot without removal and easily repaired by spraying or trowel application
CONDENSATION – DEWPOINT CHART OR DEW POINT CALCULATOR
High due to the air trapping characteristics of RockWool/FiberglassNo condensation due to complete surface bon
CORROSION UNDER INSULATION (CUI)
High due to condensation problemNo condensation thus no corrosion
REPAIR
Must shut down operation to repairNo repair is necessary for HPC® COATING
MAINTENANCE COSTS
High due to frequent maintenance required for condensation & corrosion control plus high down time, labour and material costsLow as HPC® COATING is directly sprayed without plant shut down plus the labour and material cost are much lower
LIFE SPAN
Lasts about 6 monthsSeveral years
Source: Eagle Coatings. Note: The cost comparison between Rockwool/Fiberglass vs. HPC® COATING coating for hot pipes should be made with respect to the total costs. The total costs include: material costs, installation costs, repair costs, frequency of downtime, maintenance costs, labour costs and life span. When all these costs are combined, HPC® COATING coating is superior to Rockwool/Fiberglass insulation as evident in the above comparison.

For more information and documentation on HPC Coating, visit SPI Coatings

HPC® Used Around the World

HPC® Coating Spread Rate Guide

Product % solids by volume Microns DFT mm DFT Mils DFT Spread m2/litre Spread m2/gal Spread ft2/gal
HPC 72.0 1270 1.27 50 0.57 2.1 23.1
  72.0 2540 2.54 100 0.28 1.1 11.5
  72.0 5080 5.08 200 0.14 0.5 5.77
  72.0 6350 6.35 250 0.11 0.4 4.62

HPC for Cool Room Condensation – 30°C variation

The Challenge: A client was looking to stop condensation on a wall that was an office and the room was 22°C. The other side of the wall was a cool room at -15°C with panelling. Both walls are interior to the building however for this conversation the office wall is the exterior wall.

HPC Solution

When you get over a 30 degree difference between the interior and exterior of a wall, you need some thickness, so you are only interested in the exterior side of the wall.

Why, because the hot moisture air is only on the exterior wall.

When the warm air hits the wall and sets, it cools and when it cools, it cannot hold the moisture and it shows as condensation on the side of the warm air. As warm air cools, it drops out it’s moisture.

The interior is cold and no moisture as the air conditioning unit pulled all the excess moisture out of the air and cool air does not hold moisture. You must prevent the warm moist air from setting on the cold common wall between interior and exterior.

To do this, you must apply HPC for thickness to 13mm dry thickness and over coat with Super Therm®.

This blocks the warm air from setting on the surface of anything cool, the Super Therm® helps to throw off the radiation by using emissivity to release the warmth off the surface.

You must have the thickness of the HPC to prevent the wall surface with Super Therm® on it to ever being cool that would cause the warm air still covering the exterior wall during the warm air laying on the wall and then being thrown off by Super Therm®.  You would still have some condensation without HPC.

HPC® and Top Coat Protection

If a durable protective finish is required because of the surrounding environment, such as physical, mechanical abuse or over pipes subject to vibration, apply as follows. After the last coat is applied but before it dries, wrap polyester or fiberglass mesh around the pipe with the edges slightly overlapping to provide complete coverage. Allow this to dry. Topcoat with Super Therm®.

For exterior applications subjected to WEATHERING apply Super Therm® at 2.4m2 per litre giving 425 microns WFT or 250 microns DFT. Allow to dry and cure over night.

For resistance from CHEMICALS apply Enamo Grip® Solvent (White or Coloured) or Rust Grip® at 18 m2 per gallon at 92.5 microns WFT. Allow to dry and cure over night.

For applications with HIGH HUMIDITY or SUBMERGED UNDER WATER allow the HPC® to dry then apply Moist Metal Grip.

Information needed prior to application of HPC or HPC HT

To make a right choice of products to use HPC or HPC HT we need to know:

  • What is the maximum temperature inside the pipes and valves
  • Dimensions (outside diameter and lengths) of pipes/valves/vessels or approximate square meters of insulating area
  • Location (indoor/outdoor: in this case looks like indoors)
  • What is the average ambient temperature in the location of equipment and if there is any air ventilation

Safe to Touch Temperatures

Time of contact OSHA – 5 seconds with no burn

Maximum Temp. °CDFT of HPC mmHPC Safe To Touch °CTime of Hand Contact
204.42.598.330 seconds +
232.22.5110.615 seconds +
232.2598.930 seconds +
250.05104.420 seconds +
250.01077.260 seconds +
250.01759.460 seconds ++
Summary of the tests conducted in the SPI laboratory from 1.8.18 to 30.9.18
Ambient temperature during the tests from 18°C to 27°C with moderate air movement

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