As high-value, high-risk assets, the full life-cycle safety management of ships faces challenges ranging from confined space operational risks during the construction phase to dynamic system failures and environmental load challenges during the operational phase. System integrators, IoT solution providers, project contractors, and engineering companies need to deploy high-reliability, multi-protocol compatible sensor modules in shipbuilding platforms, engine room automation systems, hull health monitoring networks, and ocean-going safety systems. This supports data fusion and decision-making loops for Safety Instrumented Systems (SIS), Asset Management Systems (AMS), Voyage Data Recorders (VDR), and shore-based remote monitoring platforms.

The Nexisense marine-specific sensor series is optimized for marine engineering environments. It covers oxygen (O₂), combustible gas (LEL), toxic gases (CO, H₂S, NH₃, etc.), vibration/acceleration, strain, temperature, pressure, and other multi-parameters. It provides explosion-proof and intrinsically safe designs with industrial-grade interfaces, and has achieved stable integration in shipbuilding and operation projects for various types of commercial vessels, oil tankers, and LNG carriers.

Core Sensor Principles and Characteristics for Marine Safety Monitoring

Nexisense modules utilize mature electrochemical, optical, capacitive, and MEMS principles to ensure long-term reliability under harsh marine conditions such as high humidity, salt spray, vibration, and EMC interference:

• Oxygen and Combustible/Toxic Gases: Uses TDLAS laser absorption spectroscopy or electrochemical principles. O₂ 0–30% VOL, combustible gas 0–100% LEL, CO/H₂S at ppm levels, resolution 0.1%, response time <30 s, explosion-proof certification (Ex ia IIC T4 Ga / Ex d IIC T6 Gb).

• Vibration and Acceleration: MEMS tri-axial accelerometer + vibration velocity sensor, frequency range 0.5–10 kHz. Monitors bearings, main engines, and propulsion shaft vibration, supporting ISO 10816 standard threshold alarms.

• Structural Strain: Fiber Bragg Grating (FBG) or resistance strain gauges. Offers micro-strain resolution and corrosion-resistant packaging, embedded in key hull nodes to monitor fatigue loads and stress concentrations.

• Temperature/Pressure: PT1000/thermocouples and piezoresistive sensors. Ranges: -40℃ to +150℃, 0–10 MPa, with explosion-proof housings and temperature compensation.

These modules support multi-parameter probe integration or independent channels, reducing wiring complexity and maintenance points.

Typical Project Application Scenarios

Nexisense sensors have verified their value in the following marine projects:

Shipbuilding Stage Confined Space Safety Monitoring
Deployed in dock segments, double bottoms, ballast tanks, pump rooms, and other restricted spaces to monitor O₂, LEL, and CO/H₂S concentrations in real-time. Integrated into mobile or fixed gas detection stations, connecting to permit-to-work systems via RS485 Modbus RTU to realize "pre-entry inspection" and continuous monitoring during operation, compliant with OSHA 1915 and IMO MSC.1/Circ.1485 specifications.

Engine Room and Power System Health Management
Installed on key components such as main engines, diesel generators, turbochargers, and bearing housings to monitor equipment status through vibration + temperature sensor fusion. Data is integrated into AMS/CMS platforms to support trend analysis, FFT spectrum diagnosis, and predictive maintenance, reducing the risk of unplanned downtime.

Ship Hull Health Monitoring (SHM)
Fiber optic strain sensor arrays embedded in high-stress areas such as the keel, deck, and bulkheads to collect strain changes caused by wave loads and cargo loading in real-time. Combined with acceleration data, this evaluates fatigue life and supports Hull Monitoring Systems (HMS) and IACS UR Z17 requirements.

Liquid Cargo and LNG Ship Cargo Tank Safety
Monitors O₂ residues in inert gases and cargo vapor (VOC/combustible gas). Interlinked with inerting systems and ventilation control to achieve closed-loop management of the IGS (Inert Gas System), complying with IGC Code and IBC Code requirements.

Summary of Marine Sensor Specifications (Reference)

Selection Guide and Integration Considerations

To match marine project requirements, integrators should focus on:

• Parameter Combination: For the construction phase, prioritize four-in-one probes (O₂+LEL+CO/H₂S); for the engine room, focus on vibration+temperature+pressure; for structural monitoring, choose FBG strain+acceleration.

• Response and Installation: Gas response <30 s, vibration <1 ms. Gas probes are recommended to be in-situ diffusion or extraction+pre-treatment; vibration sensors should be rigidly fixed to avoid loosening.

• Communication Interface: Standard RS485 Modbus RTU, supporting 4–20 mA HART, CAN, Profibus DP. Modbus registers are standardized, including concentration/vibration RMS/strain values, status alarms, and diagnostic codes.

• Environmental Protection: IP67/IP68, salt spray resistance (C5-M grade), explosion-proof/intrinsically safe certification. Operating temperature -40℃ to +70℃, vibration resistance ≥10 g.

• Power Supply: 24 V DC or 12–36 V wide voltage, power consumption <5 W, adapted for marine UPS power supply.

• Calibration and Maintenance: Gas sensors recommended for on-site verification every 6–12 months; vibration/strain sensors factory-calibrated, with periodic zero-point verification.

Integration Considerations:

• Avoid interference from strong electromagnetic fields (radar, VHF); shielded cables and equipotential grounding are recommended.

  
  

• Implement address conflict detection and bus topology optimization for multi-sensor networks.

• Enable timestamp synchronization and anomaly filtering during data fusion.

• Strictly adhere to ATEX/IECEx wiring specifications in hazardous (explosion-proof) areas.

OEM Customization and Bulk Supply Capabilities

Nexisense supports deep marine-grade cooperation:

• OEM Module Delivery: Provides bare probes, custom housings, class-approved firmware, and branded protocols, adapting to DNV, ABS, CCS, and other class requirements.

• Functional Customization: Parameter expansion, range adjustment, anti-corrosion coatings, additional wireless gateway support (LoRa/satellite), and custom Modbus registers.

• Stable Bulk Supply: Large-scale production ensures batch consistency, supporting shipbuilding batch supply agreements and spare parts inventory buffers.

• Engineering Support: Complete SDK, integration manuals, class certification coordination, and on-site commissioning guidance.

These capabilities help integrators meet strict requirements for delivery schedules, certifications, and reliability in marine projects.

Frequently Asked Questions (FAQ)

1. What is the main difference between Nexisense marine sensors and traditional portable detectors?
Optimized for continuous online monitoring, featuring explosion-proof/intrinsically safe designs, industrial interfaces, and long service life. Suitable for fixed integration and system interlinking, whereas portable units are more suitable for temporary inspections.

2. How stable are gas sensors in high-humidity and salt-spray environments?
Utilizing anti-corrosion coatings and sealed designs, they meet C5-M salt spray test standards, with <±5% drift over 12 months, eliminating the need for frequent component replacement.

3. Which communication protocols are supported? How difficult is integration with existing marine automation systems?
Mainly RS485 Modbus RTU, supporting 4–20 mA HART and CAN. Registers are standardized, with a typical integration cycle of 2–4 weeks, supporting direct mapping to AMS/PLC.

4. Do vibration sensors meet the ISO 10816 marine machinery vibration standard?
Yes, they support RMS velocity/acceleration measurement, with a frequency range covering main and auxiliary engine diagnostic needs, and can be used directly for classification threshold alarms.

5. How do structural strain sensors adapt to marine fatigue monitoring?
The FBG fiber optic solution is corrosion-resistant and immune to electromagnetic interference, featuring micro-strain resolution suitable for long-term embedded monitoring and supporting input for fatigue life prediction models.

6. Is OEM classification society certification or customized protection grades supported? What is the minimum order quantity?
Yes, we support coordination for DNV/ABS/CCS certifications and customized housings/protocols. Batches are flexible; orders of several dozen units can enjoy framework pricing and priority delivery.

7. What are the explosion-proof certification levels? Which hazardous marine areas are they suitable for?
Ex ia IIC T4 Ga / Ex d IIC T6 Gb, suitable for Zone 0/1/2 gas explosive environments, meeting requirements for high-risk compartments such as oil tankers and LNG ships.

8. In the construction and operation phases, what are the recommended typical deployment points?
Construction phase: Confined space entrances and work areas. Operational phase: Main engine/bearings in the engine room, cargo tank inerting systems, and stress concentration areas on deck, linked with ventilation/inerting systems.

Conclusion

The transformation of marine safety from passive response to active prediction, and from manual inspection to data-driven management, has become a core competitiveness of modern shipping. With multi-parameter fusion, explosion-proof reliability, and industrial interface compatibility at its core, the Nexisense marine sensor series provides a solid foundation for system integrators to build marine intelligent safety monitoring networks. It not only safeguards key risk points during construction and navigation but also assists partners in achieving comprehensive upgrades in predictive maintenance, compliance electronic logging, and shore-based remote management.

If you are advancing shipbuilding safety systems, engine room AMS upgrades, hull SHM projects, or LNG/tanker cargo safety monitoring solutions, welcome to contact the Nexisense team for detailed specifications, integration cases, class certification support, or prototype testing plans. We are committed to providing sensor solutions that stand the test of long-term marine environments, working with industry partners to enhance the inherent safety levels of ships.