What is the SmartPad System?
Pipe External Corrosion Protection for Above-Ground Piping Systems
The RedLineIPS SmartPad System from Cogbill, patent-pending, is a pioneering fiber-reinforced plastic (FRP) Wear Pad System designed to protect above-ground piping systems from external corrosion at the pipe support points. The SmartPads neither require epoxy nor welding for installation, enabling swift installation, removal, and reinstallation in minutes. This drastically reduces installation, corrosion inspection, and maintenance costs, hence significantly reducing total ownership costs.
- Patent-Pending
SmartPad System Partners
Corrosion Under Pipe Supports (CUPS)
Major Factors Leading to CUPS
In the petrochemical and gas industries, piping systems commonly rely on supporting structures, often constructed from metal materials. In this context, both environmental and mechanical factors significantly contribute to the occurrence of Corrosion Under Pipe Supports (CUPS). This is especially prevalent in coastal regions and offshore platforms, where the following factors play a crucial role in promoting CUPS:
- Mechanical Stress: Pipes often experience movement and vibration due to factors like rotating equipment, fluid flow, temperature fluctuations between day and night, and seasonal changes. Over time, these movements create friction forces between the pipe and its supporting structure, often a pipe rack. This friction erodes the pipe’s protective paint coating, exposing its bare surface to the elements and leading to pipe corrosion at the support locations.
- Moisture Retention: Limited airflow at these support regions can result in the retention of water molecules, promoting crevice corrosion.
- Metal-to-Metal: Since most pipes and pipe racks are made from metal, the electrical reaction between them will lead to galvanic corrosion.
Once corrosion initiates, corrosion cells gradually expand, deteriorating the pipe from the outside in. This process can ultimately lead to chemical leaks, resulting in asset loss at a minimum and, at worst, catastrophic failures with the potential for loss of life.
Unprotected Pipe
Corroded Pipe
The RedLineIPS SmartPad System
Leading Solution for Protecting Pipes Against External Corrosion
- Eliminates Metal-to-Metal Contact: The system’s use of non-conductive, corrosive-resistant Fiber-Reinforced Plastic (FRP) material effectively eliminates metal-to-metal contact between the pipe and its support. This crucially prevents galvanic corrosion and provides a protective barrier for the pipes.
- Saddle Design: The SmartPad features a saddle shape that provides support from underneath the pipe. This design serves multiple purposes: it prevents point-loading stress on the pipe, safeguards the pipe’s paint coating, and reduces friction and vibration that can hasten corrosion. It also completely covers the pipe section that forms a crevice with the support structure, ensuring full protection against crevice corrosion.
- Trapped Moisture Elimination: The closed-cell Hydroseal gasket, featuring a NEMA-4 watertight seal (to learn more click here), acts as a strong moisture barrier. It efficiently prevents moisture from ever entering between the SmartPad and the pipe, substantially reducing the risk of corrosion.
- Streamlined Installation and Maintenance: The SmartPad System is engineered for rapid and hassle-free installation, removal, and reinstallation. Crucially, it eliminates the need for welding or epoxy, allowing for swift implementation within minutes, all without necessitating line shutdowns or permits. This simplicity enhances cost-efficiency and minimizes operational downtime.
- Enables Visual Corrosion Inspection: The straightforward installation and removal process facilitates cost-effective visual corrosion inspections, serving as a valuable alternative to pricier inspection techniques such as ultrasound and radiography.
- Enables Visual Corrosion Inspection: The straightforward installation and removal process facilitates cost-effective visual corrosion inspections, serving as a valuable alternative to pricier inspection techniques such as ultrasound and radiography.
- Overall Ownership Costs: The SmartPad System not only significantly cuts installation and inspection expenses, while ensuring uninterrupted production, but it also demands minimal training for installers, lowers the risk of installation errors, and necessitates fewer parts in inventory. These factors collectively lead to a substantial reduction in total ownership costs, positioning the system as a strategic solution for combating pipe external corrosion.
Check out an article featuring SmartPads by World Pipeline Magazine –
SmartPad System Components
Hover Over Components to View More Info
FRP SmartPad
FRP SmartPad
Constructed from multiple layers of continuous-strand mat impregnated with premium-quality vinyl ester resin. These pads exhibit exceptional UV stability and wear resistance, undergoing rigorous load testing in extreme temperatures and conditions. This durability makes them well-suited for challenging environments like coastal regions, offshore platforms, etc.
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Hydroseal Gasket
Hydroseal Gasket
A closed-cell elastomer engineered to establish a waterproof, NEMA-4-rated, watertight seal between a pipe and the FRP SmartPad. Conforming to the pipe's surface upon compression, it eradicates moisture traps between the pipe and the pad. Diverse material choices exist to accommodate various corrosive chemicals and extreme temperature requirements.
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SmartBands
SmartBands
Heavy-duty, non-corrosive, continuous-strand fiber-reinforced polymer straps are employed to securely fasten the SmartPads to pipes, providing exceptional strength and retention force. These straps feature square teeth for a long-lasting grip, and their smooth inner surface, coupled with low-profile buckles, ensures their safety for use on coated surfaces.
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SmartTool
SmartTool
Specifically designed for tightening the SmartBands, they ensure a secure and long-lasting fit. Available in manual, mechanical, and pneumatic variants, its ergonomic design easily applies high-tension forces to create the required watertight seal between the pipe and SmartPad. It also includes a built-in clipping mechanism to cut off excess banding.
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For more information on System Components –
Quick SmartPad Installation Process
Step #1 - Loosely Attach SmartBands Around Pipe
Step #2 - Insert SmartPad Between SmartBands & Pipe
Step #3- Tighten SmartBands With SmartTool Securely
SmartPad System Benefits
Get a Free Quote for the SmartPad System
Office Location
RedLineIPS by Cogbill
2325 South Main Street Vidor, TX 77662
+1 (409) 768-1419
