In hazardous industrial environments, reliable and instantaneous communication is vital for mobile worker safety and operational efficiency. To overcome the operational limitations of conventional analogue radio equipment, SK Incheon Petrochem implemented an advanced IP push-to-talk (IP-PTT) communication platform integrated with explosion-proof smart devices from Pepperl+Fuchs.
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 operates in the petroleum and chemical sectors. Its core petroleum division refines and supplies petrol, kerosene, jet fuel, diesel, liquefied petroleum gas (LPG) and marine fuel oil.
Petroleum refineries are demanding environments, characterised by high levels of machinery noise, large sites and potentially explosive gas atmospheres. Continuous real-time coordination among plant operators, central control rooms, emergency response crews and mobile workers is essential to daily operations at the SK Incheon Petrochem refinery. For years, field operations relied almost exclusively on conventional analogue radio frequency (RF) wireless systems.
However, this legacy RF infrastructure increasingly created operational bottlenecks. Bulky and stationary equipment limited mobility and made hands-free work difficult for staff moving through complex plant structures. The ageing hardware also suffered from declining manufacturer support, persistent audio static and severe signal attenuation in remote areas of the plant. The analogue RF system could not transmit digital data or process photos, or connect with modern enterprise IT tools. The communications infrastructure had to be replaced to support workers and keep operations running smoothly.
Mobile workers needed a modern system that offered radio-grade low latency, hands-free operation and certified explosion protection. It also had to work with existing RF equipment and be introduced without disrupting refinery operations. When SK Incheon Petrochem began modernising its communications 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 for use in hazardous refinery zones. Designed for rugged industrial environments, the compact devices fit in workwear pockets so workers can carry them throughout the site.
With the Smart-Ex 03, mobile workers can contact remote support by phone or video call from the field. The front camera provides clear images, and the programmable side button can be configured for push-to-talk or emergency calls, allowing workers to call for help quickly.
The Smart-Ex 03 features a ‘glove mode’ that increases touchscreen sensitivity so workers can operate it precisely while wearing gloves. Workers can also lock the device by double-tapping the home screen, avoiding the need to feel for the side button. Both left- and right-handed workers can use this feature.
To address the high levels of background noise in active refinery units, the system uses AI noise cancellation and automatic volume control to improve voice clarity. With RSM-Ex 01 BT Bluetooth microphones, field operators can communicate hands-free while carrying out complex maintenance tasks.
Compatibility between the existing analogue equipment and the new IP-PTT network was a key requirement. Radio over IP (RoIP) gateways, dispatcher PCs and dedicated push-to-talk servers allow field engineers using Smart-Ex 03 devices over LTE to talk directly to colleagues using conventional RF radios. The Smart-Ex 03 platform also carries Android Enterprise Recommended certification and Google Silver Partnership status, with operating system and security updates until 2032 and centralised IT management.
Efficient and flexible field operations
The transition has changed daily field operations. Workers can now exchange instant voice messages, share photos, transmit field data and access remote technical support directly from hazardous areas of the plant. SK Incheon Petrochem and Pepperl+Fuchs are considering further expansion, including next-generation remote speaker microphones (RSM-Ex), additional specialist explosion-proof accessories and software enhancements to extend IP-PTT services to more operational units.
The project met SK Incheon Petrochem’s technical and operational objectives. The upgraded communications infrastructure has eliminated coverage blind spots, improved voice clarity through AI noise cancellation and laid the groundwork for digital twin applications. The refinery can now use explosion-protected smart devices in the field while maintaining communication with teams using existing radios.
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