The marine industry presents some of the most demanding operational environments for electrical and heating equipment. From the corrosive effects of saltwater to extreme temperature fluctuations and constant vibration, marine applications require specialized solutions that can withstand conditions that would quickly destroy standard industrial equipment.

The Unique Challenges of Marine Environments

Marine environments create a perfect storm of challenging conditions that test the limits of electrical components. Saltwater exposure leads to accelerated corrosion, while the constant motion of vessels creates persistent vibration that can cause mechanical failure in poorly designed systems. Temperature variations from engine rooms to refrigerated cargo holds demand equipment that can perform reliably across wide thermal ranges.

The consequences of equipment failure at sea extend far beyond simple downtime. A failed temperature sensor in a ship's engine room could lead to catastrophic engine damage, while heating system failures in offshore platforms can compromise both safety and operational efficiency. This reality drives the need for marine-grade components that prioritize reliability above all else.

Specialized Cable Solutions for Marine Applications

Cables used within marine applications must withstand conditions that would quickly degrade standard electrical cables. Saltwater corrosion, UV exposure, and mechanical stress from ship movement require cables with enhanced protective properties. Mineral insulated (MI) cables offer superior performance in these environments due to their robust construction and inherent resistance to moisture ingress.

The copper sheath of MI cables provides excellent corrosion resistance when properly selected and installed. Unlike plastic-insulated cables that can degrade under UV exposure and temperature cycling, MI cables maintain their integrity throughout extended marine service life. This reliability is crucial for applications such as navigation equipment, engine monitoring systems, and safety installations where failure is not an option.

For marine heating applications, specialized heating cables must resist both corrosion and mechanical damage. These cables often incorporate multiple protective layers and are designed to maintain consistent heat output even when subjected to the constant motion and vibration typical of marine environments.

Temperature Monitoring in Marine Operations

Accurate temperature monitoring is critical across numerous marine applications. Engine rooms require continuous monitoring to prevent overheating and ensure optimal performance. Refrigerated cargo systems depend on precise temperature control to maintain product quality during long voyages. Offshore platforms use temperature sensors to monitor process equipment and ensure safe operation in challenging conditions.

Marine temperature sensors must be designed to withstand not only the corrosive marine environment but also the wide temperature ranges encountered in different areas of a vessel. From the heat of engine compartments to the cold of refrigerated spaces, sensors must maintain accuracy and reliability across these extremes.

The installation of temperature monitoring systems in marine environments requires careful consideration of sensor placement, cable routing, and protection from physical damage. Sensors must be accessible for maintenance while being protected from the harsh conditions that could compromise their operation.

Heating Solutions for Marine Environments

Marine heating applications range from engine preheating systems to cargo temperature control and crew comfort systems. Each application presents unique challenges that require specialized heating solutions designed for marine service.

Engine preheating systems must operate reliably in the demanding environment of engine compartments, where they are exposed to oil, fuel, and high temperatures. These systems often use specialized heating elements that can withstand contamination and provide consistent performance over extended periods.

Cargo heating systems require precise temperature control to maintain product quality during transport. Whether heating heavy fuel oil to maintain proper viscosity or maintaining temperature-sensitive cargo, these systems must provide reliable performance throughout the voyage.

Process heating on offshore platforms presents additional challenges, including the need for explosion-proof equipment and systems that can operate safely in potentially hazardous environments. These applications require heating solutions that meet stringent safety standards while providing the reliability essential for offshore operations.

Safety and Reliability Considerations

Safety in marine applications cannot be compromised. Equipment failures at sea can have serious consequences, making reliability the primary consideration in component selection. This drives the need for proven technologies and robust designs that have demonstrated their ability to perform in marine environments.

Redundancy is often built into critical systems to ensure continued operation even if individual components fail. Temperature monitoring systems may include multiple sensors and backup systems to ensure that critical processes remain monitored even in the event of equipment failure.

Regular maintenance and inspection programs are essential for maintaining the reliability of marine heating and temperature monitoring systems. However, the design of these systems must minimize maintenance requirements while ensuring that necessary maintenance can be performed safely and efficiently.

Industry Standards and Certification

Marine applications are subject to strict industry standards and certification requirements. Equipment must meet standards set by organizations such as the International Maritime Organization (IMO) and various classification societies. These standards ensure that equipment can perform safely and reliably in marine environments.

Certification processes verify that equipment meets the demanding requirements of marine service. This includes testing for corrosion resistance, vibration tolerance, and performance under extreme temperature conditions. Only equipment that successfully passes these rigorous tests should be considered for critical marine applications.

Compliance with these standards is not just a regulatory requirement but a practical necessity for ensuring reliable operation in marine environments. The cost of equipment failure at sea far exceeds any savings from using non-certified components.

Future Developments in Marine Technology

The marine industry continues to evolve, with new technologies and applications creating additional demands for specialized heating and temperature monitoring solutions. The growth of offshore renewable energy installations, increased automation in shipping, and stricter environmental regulations all drive the need for advanced marine-grade equipment.

Digitalization is transforming marine operations, with smart sensors and connected systems providing enhanced monitoring and control capabilities. These developments require heating and temperature monitoring equipment that can integrate with modern control systems while maintaining the reliability essential for marine service.

Environmental considerations are also driving innovation in marine technology. More efficient heating systems and improved temperature monitoring can contribute to reduced fuel consumption and lower emissions, supporting the industry's efforts to minimize environmental impact.

To Conclude

Marine applications demand the highest levels of reliability and performance from heating and temperature monitoring equipment. The harsh conditions encountered at sea require specialized solutions that can withstand corrosion, vibration, and extreme temperature variations while maintaining consistent performance.

Success in marine applications depends on selecting equipment specifically designed for marine service, ensuring proper installation and maintenance, and adhering to industry standards and certification requirements. As the marine industry continues to evolve, the demand for advanced, reliable heating and temperature monitoring solutions will only continue to grow.

The investment in marine-grade equipment pays dividends through reduced maintenance costs, improved safety, and enhanced operational reliability. For marine operators, the choice of heating and temperature monitoring equipment is not just a technical decision but a critical factor in ensuring safe and efficient operations at sea.

Recognising the increasing challenges that our clients face, we are proud of the work that our engineers do to bring the latest technological advances to our cabling, heating and temperature measurement solutions. 

Our clients work across the globe in some of the most challenging environments there are and here are a few examples of Solutions we have provided which provide greater stability and more accurate readings.

When it comes to a hydrocracker or hydrotreater unit, our range of specialist multi-point assemblies enable a full 3D temperature profile to be carried out.  We’re also able to offer a unique supply chain solution using our AeroPak mineral insulated cable and laser-welded systems.

An area of particular concern for fluid catalytic cracking units is the harsh operating conditions that they need to work in.  This where our advanced temperature measurement solutions are highly effective.  Clients can choose either our dip-leg or catalyst cooling measurement solutions.  For highly abrasive process conditions, we also have specially coated thermowells that have the ability to operate in such environments.

For the actual catalytic process, we’re fully aware of space being limited, consequently we’ve developed a range of miniature specialist temperature assemblies using our AeroPak mineral insulated cable.  This includes the AeroMini, with an OD of 3mm, it has multiple individual measuring points found on its length.

Other locations where extreme temperatures are also a major factor for consideration include sulphur recovery units.  These are widely recognised for having a harsh process temperature. Our products are frequently chosen due to their ability to ensure the safe and efficient operation of these units.  Storage tanks are certainly another area where there’s great demand for temperature assemblies. 

Cryogenic applications such as LNG storage require an extremely high level of accuracy, and over the years we’ve worked hard to develop the design of our temperature assemblies to meet these demands.  We’re able to supply our RTD or thermocouple assemblies with extended lengths using our patented AeroPak mineral insulated cable.

If you’d like to discuss any of the above or learn about other products contact the team on 029 2081 4333 or sales@okazaki-mfg.co.uk.

Ion thrusters are used in a variety of applications, from keeping satellites in their correct position to propelling spacecraft throughout our solar system. For each thrust that one of these thrusters creates it uses a relatively low rate of propellant consumption, so they require significantly less propellant than what would be needed with chemical propulsion. In some cases where insufficient chemical fuel cannot be carried on the spacecraft Ion propulsion is the only solution to complete the desired mission.

According to NASA Ion Thrusters are now being used in over 100 of their Earth orbit communication satellites to keep them in their desired locations, and three NSTAR ion thrusters are enabling the Dawn spacecraft (launched in 2007) to travel deep into our solar system. And technology is being developed now that could one day see Ion Thrusters propelling humans to Mars.

How do Ion Thrusters Work?

Ion Thrusters work by ionizing a fuel by adding or removing electrons to produce ions. Most thrusters ionize the propellant by electron bombardment – a high energy electron (negative charge) collides with a propellant atom (neutral charge), releasing electrons from the propellant atom and resulting in a positively charged ion.

The thrust comes from an ion stream at very high velocities. This is called Plasma. Plasma has some of the properties of gas but is affected by electric and magnetic fields. A typical plasma thruster will have a heater to generate the heat needed to allow the plasma to start flowing in the Ion Thrusters. The plasma carries a current between the ionizing anode and a cathode. The current in turn generates a magnetic field at right angles to the electric field, and thereby accelerates the positive ions out of the engine to create the required thrust.

Heater solutions

At the heart of an Ion Thruster is the chamber that holds the cathodes. The cathodes are a part of the plasma generating system which give these thrusters their long life. Attached to the cathodes you will have heaters which will generate the required heat to allow the plasma to start flowing within the Ion thruster.

As mentioned earlier Ion Thrusters can have a very long lifetime so all elements involved in their construction are of course expected to meet the same lifetime of use. At Okazaki along with our colleagues at ARi, we have developed heater cable which is durable and offers a long lifetime suitable to be used in Ion thrusters.  

Development of our heating solutions required researching the latest materials and technologies to produce some of the highest quality heaters possible which can reach the high temperatures required to ignite the plasma within Ion thrusters, yet still provide the long-life reliability needed for deep space applications. We have achieved this by using refractory metals that allow us to reach temperatures that base metals are unable to attain.

The Future

Ion Thruster technology is evolving all the time as our horizons broaden deeper and deeper into space so at Okazaki our engineers continue to develop heater cable solutions to meet these ever-expanding demands.

The future is very exciting.

For more information our ‘Heaters for Ion Thrusters’ Datasheet can be found here. Alternatively contact sales@okazaki-mfg.co.uk if you’d like to discuss our heaters and other products.

Micropak – Small in Name, Huge in Performance

In our last article, we focused on our specialism in vacuum operations. This piece features our specific range of Micropak heaters. With temperature being our core focus at Okazaki, we’re particularly proud to deliver our expert range of mineral insulated heaters perfectly suited to the vacuum industry.

The Micropak heater has been chosen by many of our clients across the globe as their ideal choice of heating solutions in varying applications such as ion implants, patterning, removing doping and valve heaters.

Certainly in the vacuum operation industry, we’re fully aware of the importance that you have in finding heating solutions that are highly effective and able to operate in extreme conditions. As the world’s leading manufacturer of mineral insulated cable, we’ve made it our commitment to design solutions that meet these extensive temperature needs. In fact, we’ve spent over the past 60 years, developing the latest products and using leading-edge technologies to meet the needs of our extensive range of clients. We also know that accuracy and reliability are extremely important for your ability in maintaining production and operation.

If flexibility is a key factor in your vacuum operation needs, the Micropak heaters certainly deliver. Being ultra-small, they offer far greater flexibility. They benefit from a small bend radius as a ratio to the outside diameter of the heater. Not only that, the units can be coiled and freely formed into complex shapes as desired. This makes them particularly ideal where space is limited.

As for the range of applications that the Micropak heaters are suitable, we’ve seen our Micropak heaters used for a wide range of applications. These have included analytical instrumentation devices, fuel cells and vacuum applications. You’ll also be able to choose from an extensive range of diameter, lengths, materials and terminations. Certainly, it’s highly feasible for a wide operating range to be achieved of between -200°C to 500°C.

At Okazaki, we’ve also had a strong belief that one size doesn’t fit all. So for this reason, we’re able to design the Micropak heaters bespoke to your specific application. These include conductor coil configuration in Model MP11; providing different outputs at specific points of the heater.

A further benefit of the Micropak heater is that it also has the same diameter hot and cold sections with no external join. This helps remove mechanical joint failure which also makes it ideal for installation into vacuum sealing flanges.

Experts in Heating for the Vacuum Industry

If you’re working in the semi-conductor industry, you’ll no doubt appreciate the importance of effective high temperature plate heaters when it comes to choosing the right products for vacuum operations. With temperature being our business, at Okazaki we’ve always specialised in delivering solutions that have the capability to operate in extreme conditions. Certainly superior performance and the ability to cater for a uniform surface temperature is absolutely key.

We know how you need solutions that adhere to very specific conditions. All of our plate heaters are fully manufactured and assembled at our dedicated facilities. As we use our own carefully designed mineral insulated heater thermocouples, you can be guaranteed that each unit is finished to the highest of standards. In fact, all of our units are extensively tested to ensure uniformity within 1% to make sure that they have the capability to operate to 1000°C.

We also recognise that one product doesn’t fit all. Which is why we’re able to offer a range of plate heaters in a variety of shapes and sizes – including round and square. Materials-wise, we’re able to give you a wide choice including aluminium Inconel alloys and stainless steel, amongst others.

Our Aeroheat heater in particular is a long-life mineral insulated metal sheathed heater. Having been manufactured from a single diameter cable with no internal joins to eliminate mechanical failure points, the heater assemblies benefit from an integrated un-heated cold section. This means that there’s no additional need for costly infrastructure such as water cooling pipe work or alternative systems to maintain lower temperatures. In addition to this, you’ll also look forward to a reduction in overall plant running cost – helping you to meet environment operating costs.

You can simply integrate the Aeroheat heater and its terminations into sealing flanges or ports, which means that full sealing is maintained – even in the highest of vacuum atmospheres.

Particularly beneficial in all forms of deposition equipment, the Aeroheat makes for an excellent choice in ALD, CVD, ion plating and sputtering. Precise temperature control can soon be achieved by arranging a set of multiple panel heaters. This is even possible with the largest of today’s and future glass substrates including Generation 10 and above. Plus, a circuit partition is also possible in order to compensate for any local temperature decrease caused by the carriers.

Out of this World Sensors and Heaters

When it comes to some of the most challenging environments known and even unknown to man, there can be few locations that are as challenging as the moon.  So, when Okazaki was challenged with delivering heaters and sensors for the NASA Mars Curiosity Rover, this certainly presented a worthy proposition.

At Okazaki, we’ve always understood that our valued clients across the globe require extreme levels of product reliability.  We know that time is money, and any impact on production or service can result in serious implications both financially and regarding safety.  We also know that our clients appreciate that world-class quality is our benchmark.

For the purpose of the NASA Mars Curiosity Rover, NASA opted to use Micropak heaters in order to heat the sampling tubes inside the vehicle.  The challenge here was to benefit from greater flexibility when space is particularly paramount. With a small bend radius as a ratio to the outside diameter of heater, the units proved flexible thanks to their ability to be coiled and freely formed into complex and desired shapes.

As part of their investigations, demands on working in an extreme temperature range were certainly met thanks to the operating range of -200 to 500°C which can be achieved by the Micropak heaters.

A further benefit to the project was that the Micropak heater has the same diameter hot and cold sections.  Also, it has no external join which reduces the risk of mechanical joint failure while at the same time as being suitable for being installed in vacuum sealing flanges.

At Okazaki, our engineers and developers are constantly looking to use the latest technical advances to improve the efficiency and safety of our products.  For more info on how our heating and temperature sensors can be used in extreme working environments, please contact Leona Lilford