Smart devices transform SK Incheon Petrochem field operations

SK Incheon Petrochem is a major South Korean energy and petrochemical producer headquartered in Seohae-gu, Incheon. As part of the SK Group the company maintains operational portfolios in the petroleum and chemical sectors. Its core petroleum division encompasses the refining and supply of gasoline, kerosene, jet fuel, diesel, liquefied petroleum gas (LPG), and marine fuel oil.

Petroleum refining facilities present exceptionally demanding physical environments characterised by high ambient machinery noise, vast physical footprints, and potentially explosive gas atmospheres. Continuous real-time coordination among plant operators, central control rooms, emergency response crews, and mobile workers is essential within the SK Incheon Petrochem refinery to maintain daily operational integrity. For years, field operations relied almost exclusively on conventional analogue radio frequency (RF) wireless systems.

However, this legacy RF infrastructure increasingly created operational bottlenecks in the fast-paced refinery environment. Analog RF radios offered limited mobility because devices were bulky and stationary, hindering hands-free tasks for mobile workers moving through complex plant structures. In addition, the aging hardware suffered from declining manufacturer support, persistent audio static, and severe signal attenuation in remote plant zones.

Crucially, legacy analogue RF technology could not transmit digital data, process photos, or connect with modern enterprise IT tools. The communications infrastructure had to be replaced in order to support workers and ensure smooth and efficient operations.

Mobile workers required a modern system that delivered radio-grade low latency, hands-free usability, certified explosion protection, and zero disruption to ongoing refinery operations, while remaining compatible with existing legacy RF equipment. But when SK Incheon Petrochem initiated its communication modernisation drive in June 2025, finding a suitable replacement proved challenging.

A solution for every challenge

After some trial and error, a proof of concept led to the selection of Pepperl+Fuchs intrinsically safe smart devices combined with Gram Mobile's IP-PTT radio application and SK Telecom's private LTE (P-LTE) network.

Pepperl+Fuchs supplied several hundred Smart-Ex 03 DZ2 smartphones alongside RSM-Ex 01 BT Bluetooth remote speaker microphones and explosion-protected accessories. The Smart-Ex 03 smartphones hold mandatory South Korean KCs explosion safety certification under the Occupational Safety and Health Act, guaranteeing safe operation in hazardous refinery zones. Designed specifically for rugged industrial environments, the compact devices fit conveniently into work attire pockets, providing mobile workers with continuous availability and physical mobility.

With the Smart-Ex 03, mobile workers also have the option of contacting remote support by phone or video call at any time in the field. The front camera guarantees clear images. The freely programmable side button of the Smart-Ex 03 can be customised for the appropriate application. For example, it can be configured as a push-to-talk or emergency call button so that mobile workers can quickly call for help at their current location in an emergency.

To ensure that the Smart-Ex 03 can always be used optimally, even under adverse conditions, it features a so-called "glove mode". This mode increases the sensitivity of the touchscreen so it can be operated precisely even when wearing gloves. Thanks to the double-tap feature, the device can be locked by simply double-tapping on the home screen. This eliminates the need to feel for the on/off button on the side, which can be a challenge when wearing gloves. In addition, both left- and right-handed workers benefit from this feature.

To solve the severe background noise of active refinery units, the solution incorporates advanced AI noise cancellation and automatic volume control, delivering clear voice transmissions that outperform legacy RF radios. Coupled with RSM-Ex 01 BT Bluetooth microphones, field operators can communicate hands-free while carrying out complex maintenance tasks.

Seamless interoperability between legacy analogue technology and the new IP-PTT network was a key demand for SK Incheon Petrochem that was achieved through Radio over IP (ROIP) gateways, dispatcher PCs, and dedicated PTT servers. This hybrid architecture allows field engineers using Smart-Ex 03 devices over LTE to talk directly to personnel equipped with conventional RF radios, ensuring uninterrupted site-wide communication. Furthermore, the Smart-Ex 03 platform carries Android Enterprise Recommended certification and Google Silver Partnership, assuring SK Incheon Petrochem of long-term OS and security updates until 2032 as well as centralised IT management.

Efficient and flexible in field operations

The transition has changed daily field workflows significantly. Workers are now able to exchange instant voice messages, share photos, transmit field data, and access remote technical support directly from hazardous plant areas. SK Incheon Petrochem and Pepperl+Fuchs are considering further project expansions, including the introduction of next-generation Remote Speaker Microphones (RSM-Ex), additional specialised explosion-proof accessories, and continuous software enhancements to scale IP-PTT services across broader operational units.

The successful implementation of Pepperl+Fuchs mobile devices and IP-PTT infrastructure has fully satisfied SK Incheon Petrochem's technical and operational objectives. Modernising the communications infrastructure has eliminated coverage blind spots, dramatically improved voice clarity through AI noise cancellation, and established a secure foundation for enterprise digital transformation and digital twin applications. The project shows how explosion-protected smart devices can reliably replace legacy radio hardware while driving comprehensive digital transformation.