Private 5G networks, once the stuff of futuristic speculation, are now being deployed to streamline complex plant operations. This transformative potential was the focal point of a recent conversation between Geoffrey Cann, a renowned digital innovation specialist in the oil and gas sector, and Mehmet Yavuz, the chief technology officer and co-founder of Celona.
The Connectivity Conundrum
For decades, industrial facilities have grappled with the limitations of traditional networks. Wi-Fi, while ubiquitous in office environments, falters in sprawling, metal-dense environments like refineries and petrochemical plants. The signal struggles to penetrate steel structures, and the required number of access points becomes both impractical and costly.
Public cellular networks offer another option but come with their own set of challenges. Coverage can be spotty in remote locations where many plants operate. Moreover, reliance on public networks raises concerns about data security and offers little control over network performance - a critical issue when downtime can result in millions of dollars in losses.
In an industry where continuous operation is paramount and safety is non-negotiable, these connectivity challenges have long been a thorn in the side of progress.
Enter Private 5G
Private 5G networks are poised to address these challenges head-on. Offering the control and security akin to Wi-Fi, coupled with the expansive range and reliability of cellular networks, private 5G grants facilities unprecedented oversight over their connectivity infrastructure. Facilities can now dictate quality of service parameters, ensure stringent data security protocols, and maintain seamless connectivity with significantly fewer access points than traditional systems require.
“Private 5G allows us to cover vast industrial areas with significantly fewer access points than Wi-Fi,” Mr. Yavuz explained. “In some cases, what would require hundreds of Wi-Fi access points can be accomplished with just a handful of 5G nodes.”
This efficiency not only reduces infrastructure costs but also simplifies network management. Enterprises gain full oversight, enabling them to prioritize critical communications and tailor security protocols to their specific needs.
Connected Workers: The Vanguard Use Case
One of the most immediate benefits of private 5G networks is the empowerment of connected workers. Traditionally, plant operators relied on paper-based processes - a method rife with inefficiencies and prone to error.
By eliminating manual workflows, workers can access real-time data and digital work orders on devices like iPads and smartphones. Celona’s 5G LAN certified device ecosystem ensures compatibility across a range of industrial equipment.
In one notable case, a refinery implemented a private 5G network to support its workforce. The result? A reduction of turnaround time by two weeks, translating into millions of dollars saved. Workers could communicate via live video conferencing with remote experts, upload high-definition images, and receive instantaneous support - all critical in addressing issues swiftly and maintaining operational continuity.
Enhancing Safety and Security
Safety is the bedrock of industrial operations, and private 5G networks are bolstering this foundation.
By deploying cameras in previously unreachable areas, facilities can monitor remote or hazardous zones in real-time. Automated gate controls and perimeter surveillance enabled with wireless connectivity enhance security protocols without the need for expensive cabling that was needed in the past.
In emergency situations, the availability pervasive connectivity can be lifesaving. Workers equipped with communication devices can access critical information on the spot and coordinate responses swiftly, minimizing risks and potential damages.
Integrating IoT and Advanced Technologies
The private 5G framework paves the way for the full integration of Internet of Things (IoT) devices, enabling the deployment of artificial intelligence and predictive maintenance applications. Refineries can now connect hundreds of previously unconnected sensors to monitor critical operations - from pump efficiency to environmental compliance - facilitating a proactive approach to maintenance.
Advanced use cases are emerging:
- Robotics and Automation: Autonomous vehicles and robots can navigate complex environments, performing tasks ranging from inspections to material handling with precision and efficiency.
- Thermal Imaging and Remote Diagnostics: Workers can utilize devices equipped with thermal cameras to detect anomalies in equipment. These insights, shared over the network, allow experts - potentially located anywhere in the world - to diagnose issues in real-time.
Integrated advanced IoT, made feasible through private 5G connectivity, enables Digital twin technology, allowing operators to create real-time simulations of their plants. This advancement drives a shift toward predictive maintenance, reducing unplanned downtime and cutting maintenance costs.
Overcoming Historical Challenges
The industrial environment is unforgiving for wireless signals. Dense metal structures create interference, and covering expansive areas has historically required extensive infrastructure.
Private 5G networks address these issues head-on. The technology is designed to handle interference more effectively than Wi-Fi, and the enhanced signal propagation covers greater distances with fewer nodes.
Cost and deployment efficiency are additional advantages. Compared to the extensive cabling and numerous access points required for Wi-Fi, private 5G networks can be implemented swiftly - often within four to eight weeks. This speed is crucial for industries where time is money.
Real-World Success Stories
The impact of private 5G networks is not theoretical. LyondellBasell, one of the world’s largest plastics, chemicals, and refining companies, has embraced this technology across its facilities.
The scale of deployment is massive, covering thousands of acres. Applications are diverse, supporting everything from connected worker initiatives to advanced automation systems.
In another example, facilities are utilizing private 5G for wireless backhaul in remote areas, supporting transient operations like temporary training facilities without the need for extensive infrastructure investments.
The Convergence of Network Technologies
An intriguing development is the integration of public cellular services with private 5G networks. This hybrid approach enhances connectivity for contractors and visitors who rely on public networks.
Imagine a single network infrastructure that supports multiple technologies. It simplifies management and operations, providing seamless connectivity regardless of the device or service provider.
This convergence represents a significant step toward a unified network infrastructure, reducing complexity and improving user experience.
Looking Ahead: The Future of Industrial Connectivity
Advancements in 5G technology continue at a rapid pace. Upcoming releases promise even greater capabilities, with potential applications that are particularly valuable for the “carpetless” environments of industrial operations.
OT equipment are mostly wired today as they are mission critical and failure or security threats can cause a major disruption to plant operations. IT/OT convergence is the holy grail of industrial networks and private 5G has the potential to accelerate IT/OT convergence, untether the OT network while still maintaining high reliability and the IT/OT airgap security standards needed for this convergence.
Advice for Industry Leaders
For decision-makers contemplating this shift, the considerations are multifaceted.
- Evaluate Current Limitations: Understand where existing networks fall short in meeting operational needs.
- Assess Benefits: Consider how private 5G can address specific challenges, improve efficiency, and enhance safety.
- Implementation Strategies: Starting with high-return-on-investment use cases like connected workers can demonstrate immediate value. Partnering with experts, such as Celona, can facilitate swift deployment and provide the necessary support.
The adoption of private 5G networks represents a significant leap forward for the oil and gas industry. The benefits are tangible: improved efficiency, enhanced safety, and a solid foundation for future technological advancements.
As industries continue to navigate the complexities of modern operations, embracing innovative solutions like private 5G is not just advantageous - it may well be essential for staying competitive in a rapidly evolving landscape.
