A metal scupper

Abstract

A metal scupper 1 comprising a walled funnel 2 having an inlet 3 and an outlet 4, and internally mounted annularly therebetween to the walls of the scupper, a layer of intumescent material 6. The laye

Description

Field of the Invention

[0001] The present invention relates to metal scuppers, more particularly metal scuppers comprising at least one layer of intumescent material. Background to the Invention

[0002] A scupper is an opening from within the containing wall of an open structure, such as the deck of a ship allowing drainage of water therefrom. Scuppers are typically provided in boats and ships to allow seawater from waves and spray as well as rainwater to drain from decks into the sea. As well as open decks, scuppers are also routinely used within closed deck areas to drain black and grey waters, as well as other such liquids from any recreational areas, service areas and public and private spaces within a ship.

[0003] Scuppers are conventional funnels with an inlet to receive water and an outlet through which the water passes through. This arrangement then funnels the water away from the deck in a controlled manner.

[0004] Conventionally scuppers consist of an opening through the ship bulwarks, but are now more commonly provided, particularly in steel-built ships, as a steel funnel structure set into the deck and opening flush within.

[0005] At the lower end of the funnel structure, a pipe connected to the scupper leads water to the exterior of the ship’s hull or internal holding tanks, or directly overboard.

[0006] Whilst non-combustible scuppers in this arrangement are not at risk from fire damage, a problem exists because if the opening within the scupper bowl inlet allows sea water, rainwater, and black and grey water to pass through the ship to various outlets, conversely, in the event of fire damage to any section of the scupper’s piping system which may not be non-combustible, the resulting open end of the fire damaged sections within the piping system could become a pathway for the transmission of fire, smoke or hot gases through to the outlet of the metal scupper, and then to exit at the scupper into areas serving cabins, recreational, and service areas.

[0007] The escape of heat through the metal deck scupper can also transmit heat to the metal body of the scupper which in turn will increase the surrounding steel deck temperature resulting in failure of the affective deck’s insulation classification.

[0008] Marine regulations require that items passing through apertures / open-ings within decks on seagoing vessels must be able to maintain the insulation rating of the deck concerned by restricting heat from hot gases to surpass the temperature maximum readings of the prescribed deck classification.

[0009] Any current piping system used in shipbuilding can result in the internal passage of heat caused by pipe joint failure leaving open pathways for heat to travel, or by external transmission of heat along the steel pipeline through to the walls of the metal scupper.

[0010] The conventional remedy for this heat transfer is to externally insulate the metal scupper or connecting metal pipes.

[0011] There has now been devised a metal marine deck scupper that that overcomes and / or substantially mitigates the above referenced and / or other disadvantages associated with the prior art. Summary of the Invention

[0012] In one aspect of the invention there is provided a metal scupper as defined in claim 1.

[0013] The scupper is advantageous primarily because on contact with sufficient heat or flame, as would happen during fire or combustion, the intumescent material forms an exfoliated intumescent char of intumescent. This intumescent char expands within the void of the scupper (i.e. between the inner walls of the scupper body), creating an insulation medium within the inside of the metal scupper body, which restricts and reduces the rate of heat transfer through the metal scupper and therefore to the deck the scupper is mounted into, which could well have an insulation classification rating of 15 to 60 minutes.

[0014] Preferably the at least one layer of intumescent material is provided as a water-resistant deformable sheet. The water resistance feature protects the intumescent material from degradation as a result of the water effluent and waste travelling through the scupper. It also prevents the intumescent material from being eroded way by the action of the water. One example of this is where the intumescent material is rubberised, and being rubberised is impervious to water and liquid. Suitable mounting methods may be by adhesion using an adhesive, by containment using a liner (as will be explained below) or simply just being cut to fit the space provided and held in place by friction resistance. The deformability allows the material to be moulded in place.

[0015] The metal scupper comprises a water resistant heat deformable liner having an entrance port and an exit port, both being sealingly mounted to the inside of the scupper between the inlet and the outlet of the scupper and having a body between the entrance port and exit port which is narrower than that of the scupper thereby defining a void between the walls of the liner body and a portion of the metal scupper annularly in which the intumescent material is encapsulated. The liner is preferably attached to the interior of the scupper by adhesive. Other suitable means for fixing the liner to the interior of the scupper include but are not limited to mechanical fixing, screwing or bolt and nut fixing, or chemical fixing. This provides methods for mounting and encasing the intumescent material to the walls of the metal scupper. The exit port is preferably coaxial with the outlet of the scupper. Sealingly mounted to the inside of the scupper between the inlet and the outlet of the scupper includes being sealing mounted at the inlet and at the outlet of the scupper. The liner protects the intumescent material from water and retains the intumescent material in place prior to exposure to heat. Suitable materials for the liner include but are not limited to thermoplastics or plastic / poly-thene wrap.

[0016] Sealingly mounted may be by interference fit, or by the use of adhesive bonding or other method to seal the liner with respect to the scupper in a water-resistant manner and to prevent the loss of the encapsulated intumescent material.

[0017] The liner protects the intumescent material from the water and fluid penetration travelling though the scupper, which would otherwise cause degradation of the intumescent material. And as the liner is heat deformable, on the action of heat it allows the expansion of the exfoliated intumescent char to fill the 5 central void of the metal scupper funnel. Thus, it provides a sacrificial container for the intumescent material. Preferably the liner is manufactured from a nonflammable material and is non-flammable itself. This prevents any escalation of heat from within the scupper void / interior.

[0018] It will be recognised that where the intumescent material is encapsu-10 lated by virtue of a liner, then preferably the at least one layer of intumescent material is provided in flowable form. Suitable examples of flowable intumescent materials include liquids, gels, powders or granular products. This makes it easier to fill the gap between the liner and the scupper. However, with a liner, the intumescent material may alternatively be provided as a sheet or strip as described above. But given that a liner is present in order to protect the intumescent material the requirement for the intumescent material to be water resistant is minimised, if not removed.

[0019] Suitable examples for the material of the liner include but are not limited to polythene or polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride or any other polymer that would be regarded as a plastics material that is heat degradable.

[0020] Suitable examples for the material of the intumescent material includes but are not limited to sodium silicate intumescent or graphite based intumescent or Tenmat® Intumescent (Tenmat Ltd).

[0021] The invention will now be described by way of example only with reference to the accompanying drawings in which like numerals represent like parts. Brief Description of the Drawings

[0022] Figure 1 shows a cross section of an embodiment of the scupper,

[0023] Figure 2 shows a cross section of a second embodiment of the scup per,

[0024] Figure 3 shows a cross section of a third embodiment of the scupper,

[0025] Figure 4 shows a cross section of a fourth embodiment of the scupper.

[0026] Figure 5 shows a cross section of a fifth embodiment of the scupper.

[0027] Figure 6 shows a cross section of a sixth embodiment of the scupper,

[0028] Figure 7 shows a cross section of a seventh embodiment of the scup per,

[0029] Figure 8 shows a cross section of an eighth embodiment of the scupper,

[0030] Figure 9 shows a cross section of a ninth embodiment of the scupper and

[0031] Figure 10 shows graph of the test data for the scupper. Detailed Description of the Illustrated Embodiment

[0032] Figure 1 illustrates an example of the scupper generally designated 1. The scupper 1 is in the form of a round tubular funnel 2, having an inlet 3 and an outlet 4. Around the inlet 3 is a flange 5 which is secured to or inserted into a ship’s deck (not shown) in use. The inlet 3 is therefore the part of the scupper 1 that receives water in use, and the outlet 4 is the part of the scupper where water is expelled from in use. The outlet 4 is of narrower diameter than the inlet 3 and is connected to the pipework (not shown) discharging externally of a ship’s hull or into associated tanks. In this example the scupper 1 is made from stainless steel.

[0033] Mounted annularly around the inside of the outlet 4 is a layer of intumescent material 6. In other examples multiple layers are applied. In this example the material 6 is provided as a rubberised sheet adhered using adhesive to the inside of the outlet 4. The intumescent material 6 therefore encircles the inside of the tubular outlet 4 of the scupper 1.

[0034] In use water drains through the scupper from the inlet 3 and out through the outlet 4. In the event of fire, the intumescent material 6 is exposed to the fire and begins to expand forming an exfoliated char. This char completely fills the outlet 4 in the region of the void 7. The exfoliated char in insulative and limits the heat transfer within the scupper void and further outwards to the metal scupper walls.

[0035] In figure 2 there is shown a second embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper with respect to figure 1, but comprises a thermoplastic protective liner 8. The protective liner 8 is funnel shaped and is sealingly adhered to the inside of the scupper 1 at two places annularly. The first adherence position is approximately halfway between the inlet 3 and the outlet 4 and the second adherence position is at the outlet 4. The liner 8 matches the inside dimensions of the scupper at these adherence positions, but between those two adherence positions the liner 8 has smaller dimensions than the scupper 1. There is therefore a space 9 between the protective liner 8 and the metal scupper 1, which in this position is around inside of the outlet 4. This space is filled with intumescent material 6, which could be of the type described above, but might also be in flowable, sheet or strip form.

[0036] In use, water drains through the scupper 1 from the inlet 3 and out through the outlet 4. As the protective liner 8 is sealed against the inside of the scupper 1, water does not flow behind the protective liner 8, between the liner 8 and the inside walls of the scupper 1. The protective liner 8 protects and encapsulates the intumescent material 6. In the event of heat caused potentially by fire, the protective liner 8 softens and deforms with the pressure of the intumescent exfoliation. The intumescent material expands forming an exfoliated char. This char fills the outlet 4 in the region of the void 7, which insulates the internal void area of the scupper and thereby limiting the heat transfer within the scupper void and further outwards to the metal scupper walls.

[0037] Figure 3 shows a third embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper 1 in figure 2 except that the outlet 4 for the scupper 1 is at right angles to the inlet 3. The protective liner 8 is sealed against the outlet 4 as described above and encases the intumescent material 6.

[0038] Figure 4 shows a fourth embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper 1 in figure 2, but the liner 8 is much longer and is sealed against the inside of the scupper 1 at the inlet 3 and at the outlet 4. Thus, the space 9 provided for the intumescent material 6 occupies nearly all of the internal surface of the scupper 1. The additional quantity of intumescent material markedly increased the insulative capacity of the scupper 1 within the void 7.

[0039] In use the scupper 1 works in substantially the same manner as scupper 1 in figure 2 but has a significantly improved insulation capacity and quality. The liner 8 in all embodiments is the sacrificial component of the scupper 1 having features of a protective watertight casement for the intumescent material / com-pound 6, and the ability to combust and soften under heat, allowing the activation of the dry intumescent material / compound 6 within the scupper 1.

[0040] In figure 5 there is shown a fifth embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper 1 in figure 4 but that the outlet 4 for the scupper 1 is at right angles to the inlet 3. The liner 8 is sealed against the outlet 4 as described above and encases the intumescent material 6.

[0041] In Figure 6 there is shown a sixth embodiment of the scupper generally designated 1 which is not part of the invention. The scupper 1 is substantially the same as scupper 1 but has an additional pipe extension 105 which extends internally from the outlet 4 towards the inlet 3. The pipe extension 105 is sealed to the inside of the outlet 4 and provides a water trap / overflow for water moving through the scupper 1. The pipe extension 105 is made of non-flammable plastic. Affixed to the scupper 1 around the pipe extension 105 is an annular steel retainer 106 which contacts the pipe extension 105 and provides a space 109 in which intumescent material 6 is placed. The material 6 if not adhesive or held in place with adhesive, may be in flowable form as it is encapsulated effectively by the wall of the pipe extension 105 and the retainer 106.

[0042] In use water drains through the scupper 1 from the inlet 3 and out through the outlet 4. In the event of heat potentially as a result of fire, the pipe extension 105 melts exposing the intumescent material 6 to the fire. The intumescent material 6 expands forming an exfoliated char. This char completely fills the outlet 4 in the region of the void 7. This restricts the heat from spreading through the scupper 1. The retainer 106 prevents the exfoliated char from expanding outwards into the rest of the bowl 2 of the scupper 1 rather than fill the void 7.

[0043] In Figure 7 there is shown a seventh embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper in figure 6 but incorporates a liner 8 as described with respect to figure 4. The protective liner 8 is further adapted slightly so as to wrap around the retainer 106 and the intumescent material 6 in order to encase the intumescent material 6. Therefore no pipe extension 105 is required and the protective liner 8 extends out through the outlet 4 as described with respect to figure 2 and 4. In this case the outlet of the liner 8, which forms the equivalent of the pipe extension 105 in figure 6, melts when exposed to heat. The intumescent material 6 then expands and fills the void 7 while at the same time the intumescent encapsulated by the protective liner within the inner walls of the scupper void also exfoliates in the same manner and fills the entire void with exfoliated char upon exposure to heat. The intumescent material 6 is prevented from expanding outwards into the bowl 2 of the scupper by the retainer 106 which is integral or welded to the structure of the scupper (as in figure 6), whereas there is no restriction around the inner walls of the full scupper void allowing a full exfoliation of the intumescent material.

[0044] In Figure 8 there is shown an eighth embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper in figure 6, but incorporates a thermoplastic protective liner as described with respect to figure 2. The liner is further adapted slightly so as to wrap around the retainer 106 and the intumescent material 6 in order to encase the intumescent material. I this case the outlet of the protective liner 8 forms the pipe extension which melts when exposed to heat. The intumescent material 6 then expands and fills the void 7 upon exposure to flame and heat. The intumescent material 6 is prevented from expanding outwards into the bowl of the scupper by the retainer which is integral or welded to the structure of the scupper (as in figure 6).

[0045] In Figure 9 there is shown a ninth embodiment of the scupper generally designated 1. The scupper 1 is substantially the same as the scupper in figure 7, but incorporates a protective liner 8, the main body of which is sealed against the inside of the scupper wall so that there is no gap between the liner and the scupper walls in the region of the main body of the scupper 2. There is a gap however when the protective liner 8 extends over the retainer 106 and around the intumescent material before extending into an outlet which covers the inside of the outlet of the scupper 1. This embodiment serves to protect the scupper from corrosion but also provides encasement for the intumescent material 6. The scupper 1 in this embodiment works in substantially the same way as described above with reference to figures 8 or figure 7.

[0046] In the above examples where the liner 8 protects the intumescent material and encases it, then the material 6 may be provided in flowable form (i.e. liquid, gel, powder or granular) or provided as a powder mixed with adhesive which is then pasted onto the scupper, or in the form of a sheet adhered to the inside of the scupper, or simply as a lengths of material wrapped and layered between the liner and the scupper. Where no liner is used, then the intumescent material 6 is either self-affixing, mixed with adhesive, or in some way retained mechanically in place. If no liner is present, then also the intumescent material is water resistant.

[0047] In the use of marine deck scuppers there are four classes of fire integrity and insulation as explained below.

[0048] A-0 60 MINUTES INTEGRITY AND ZERO MINUTES INSULATION.

[0049] A-15 60 MINUTES INTEGRITY AND 15 MINUTES INSULATION.

[0050] A-30 60 MINUTES INTEGRITY AND 30 MINUTES INSULATION

[0051] A-60 60 MINUTES INTEGRITY AND 60 MINUTES INSULATION

[0052] “A” class steel decks are required to prevent the passage of fire and smoke from passing through the steel deck including welds, joints etc., for a minimum of 60 minutes.

[0053] “A-0” decks do not have to prevent any temperature rise to the steel deck, but A-0 decks do have to maintain the integrity value of the deck.

[0054] “A-15”, “A-30”, and “A-60” decks all have the same integrity require ment of 60 minutes, but in turn, each also has an insulation requirement of 15 -30 or 60 minutes.

[0055] This means the deck temperature on the non-fire side of the deck, must not suffer a temperature rise over 180 C from the starting deck temperature within 15, 30, or 60 minutes depending on what classification is being tested.

[0056] Each penetration through the A class deck must also maintain the same deck classification standard.

[0057] A scupper penetrating an A-0 deck only has to prove it does not allow flames, smoke, and hot gasses through to the scupper opening.

[0058] Conversely, a scupper penetrating through an A-60 deck must prove it does not allow flames, smoke, and hot gases through the scupper, it also has to prove it does not allow the deck temperature on the non-fire side to rise above 180 C.

[0059] Therefore, the deck is insulated to A-class standards using the scuppers as described herein.

[0060] Thus, a benefit of the invention as described by all the above embodiments is that no further insulation is required in order to meet the necessary and specified standards.

[0061] The scuppers described with respect to figures 1,2, 3, 6, 8 and 9 meet the required standard for A-0 scuppers.

[0062] The scuppers described with respect to figures 4, 5 and 7 meet the required standard for A-60 scuppers.

[0063] For proof of efficacy, the inventors carried out an indicative fire test of a scupper according to the invention by a third-party fire test company according to the agreed standards for fire testing of marine scuppers.

[0064] In the test a section of marine deck had inserted within it a scupper 1 of the invention (as per that shown in and with reference to Figure 4). The deck sample had insulation within it, as would be typical for a marine deck. Temperature readings were taken 25mm away from the scupper grill on the top of the deck (A), 150 mm away from the scupper grill (B), on top of the centre of the scupper grill (C), and at three positions at the very edge of the grill (edge of the scupper) (D, E, F). The study was conducted over a period of 1 hour with a controlled fire started below the deck with the scupper 1 in place. The temperatures at each of positions A-F were measured and the results plotted in Figure 10.

[0065] The results for line B indicate the temperature as would normally be expected above an insulated deck with a fire below. A temperature of 138C was reached. However, 25mm away from the scupper grill (line A) the temperature only topped out at 84C demonstrating a surprising and substantial temperature reduction caused by the scupper according to the invention. The inventors have further demonstrated that this is due to the intumescent material exfoliating within the scupper void to insulate the scupper. This can be seen in line C which is a measurement on the top of the scupper grating. So, when the fire starts, this probe will measure the maximum heat possible as it is directly above the scupper void and there is an obstructed pathway between the fire below and the temperature probe. It can be seen that just prior to the 5-minute mark the temperature at the grill rises sharply as would be expected and markedly greater than that of the deck around. The intumescent material then expands and fills the void within the scupper and the resultant reduction in temperature and later slow rise in temperature for line C indicate the insulation effect of the intumescent exfoliate. The result is that the temperature of the grill nearly closely matches that of the deck some 150 mm away (line B). It is not until the very end of the time period is a higher temperature at the grill (line C) measured compared to the deck (B). And still, the temperature at the grill and 25mm away from the grill are well within the 180C limits for marine decks. The readings taken at the very edge of the grill (D, E, F) all result in higher temperatures than the lines A-C, but this is because the measurements are taken directly at the contact point between the metal of the scupper and the metal deck. So, there is direct conductance of heat from the outlet of the scupper, along the metal of the scupper to the rim of the scupper 1 at the inlet. This would be expected as it is metal. What is important here is that these higher temperatures are not conducted outwards to the rest of the deck as can be seen from lines A where 25 mm away from the grill the temperature is at 84 C at the end of the test and from line B where 150mm away from the grill the temperature is at 138C at the end of the test.

[0066] This study clearly demonstrates that the scupper of the invention and the combination of the exfoliated intumescent material within the scupper acts to reduce much of the heat transfer through the scupper void in the invent of fire and to the immediate surrounding deck area.

Claims

1. A metal scupper (1), the metal scupper (1) comprising a walled funnel (2) having an inlet (3) and an outlet (4), and internally mounted annularly therebetween to the walls of the scupper (1), at least one layer of intumescent material 5 (6), wherein the scupper (1) comprises a water resistant heat deformable liner (8)having an entrance port and an exit port, both being sealingly mounted to the inside of the scupper between the inlet (3) and the outlet (4) of the scupper and having a body between the entrance port and exit port which is narrower than that of the scupper (1) thereby defining a void between the walls of the liner body 10 (8) and a portion of the scupper (1) annularly in which the intumescent material(6) is encapsulated.

2. A scupper according to claim 1, wherein the at least one layer of intumescent material (6) is provided as a water resistant deformable sheet.

3. A scupper according to claim 1, wherein the at least one layer of intumes-15 cent material (6) is provided in flowable form.

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