Corrosion under pipe supports (CUPS) presents a significant integrity threat on floating production storage and offloading vessels (FPSOs), where warm, chloride-rich atmospheres and extended time-of-wetness accelerate localized corrosion processes. Because degradation initiates at concealed pipe–support interfaces, wall loss can progress undetected until intrusive inspections or monitoring reveal the damage. Congested layouts and work-at-height constraints further complicate routine inspection, increasing both operational risk and lifecycle maintenance costs.

The article outlines the primary mechanisms responsible for CUPS on FPSO topsides, including crevice corrosion formed within oxygen-starved gaps, galvanic effects caused by electrically continuous steel surfaces, and under-deposit corrosion where salts and debris retain brine. Additional contributors such as pitting, microbiologically influenced corrosion (MIC), stress corrosion cracking, and fretting-assisted corrosion are discussed within the context of warm marine climates that intensify corrosion kinetics.

To address these risks, the SmartPad System is presented as an all-non-metallic support architecture engineered to interrupt corrosion drivers directly at the interface. The design combines a fiber-reinforced polymer saddle with a bonded closed-cell gasket and fiber-reinforced thermoplastic straps, forming a sealed dielectric load path that eliminates metal-to-metal continuity while limiting electrolyte retention. Designed for cold-work installation without welding, drilling, adhesives, or cure windows, the assembly can be opened and re-secured in minutes to enable rapid visual inspections.

By linking corrosion science with practical installation and inspection considerations, the article positions sealed, removable interfaces as a targeted strategy for managing CUPS risk on FPSOs and improving long-term asset reliability in aggressive marine environments.

Key Mechanisms Covered

• Crevice / differential aeration corrosion developing in oxygen-starved gaps beneath supports
• Under-deposit corrosion driven by retained salts, debris, and brine
• Galvanic corrosion resulting from electrically continuous steel pipe and supports
• Pitting and microbiologically influenced corrosion (MIC) accelerated by warm, chloride-rich marine exposure
• Fretting-assisted corrosion caused by micro-movement that damages coatings