Refineries are among the most hostile environments for Wi-Fi. Steel pipes, massive storage tanks and dense industrial structures absorb and block Wi-Fi signals, creating dead zones where connectivity simply doesn’t reach.
Even where coverage exists, interference from industrial machinery, high RF noise and fluctuating environmental conditions make Wi-Fi unstable and unreliable. Expanding coverage requires an excessive number of access points, increasing infrastructure costs, cabling complexity and security vulnerabilities - without ever fully solving the connectivity problem.
The stakes are high too. A single hour of unplanned downtime costs refineries many thousands. A missed gas leak could endanger lives. A delayed inspection risks regulatory fines.
The maturation of private 5G technologies - purpose-built to overcome the limitations of Wi-Fi – is presenting powerful new connectivity options for mission-critical environments like these.
If you’re evaluating a strategic shift to private 5G, here’s what should be top of mind throughout the process.
1. Use cases
In oil and gas, the use cases are as varied as they are critical. When evaluating private 5G, start by identifying the use cases that matter most. Are you looking to improve connectivity for remote workers, enhance real-time video surveillance, or support machine-to-machine communication across industrial control systems? Each use case has unique demands for bandwidth, latency and device density, which will influence your network design.
Consider also the scale and complexity of your operations. Will you need to support high volumes of real-time data from sensors and autonomous systems, or maintain low-latency performance for safety-critical applications where delays aren’t an option? Also, think about how your devices will interact - are they static or mobile, ruggedised for harsh conditions, or reliant on seamless handovers across large sites?
2. RF planning
When weighing the advantages of private 5G in the context of RF planning, consider how private 5G’s use of licensed spectrum reduces interference and enhances performance compared to Wi-Fi. Evaluate the need for optimised spectrum and channel planning to ensure consistent coverage, especially in areas with dense metal structures. Also, assess how well the network can balance coverage and capacity while supporting seamless mobility for connected devices and workers in motion.
3. Network planning
For private 5G to deliver on its promise, the network must be designed for the environment - whether it’s a remote oil field or a dense refinery. This means deciding between a multi-vendor setup for flexibility, or an end-to-end solution for simplicity and performance. It also involves assessing whether the network will stand alone or integrate with existing systems, ensuring IP visibility for real-time monitoring, maintaining resilience, uptime and QoS.
Private 5G brings a host of new capabilities that give you the control, reliability and security that traditional connectivity simply can’t match. Dive into the granular details with this complete guide:
- RF coverage in steel-dense zones allow for fewer APs and related infrastructure and installation expenses
- Managing QoS configurations that prioritize specific devices and applications
- TCO Calculator to benchmark costs associated with Wi-Fi vs Private 4G/5G deployment
- Know your considerations with the private 5G checklist
4. Security
Private 5G offers robust security capabilities that extend beyond what traditional networks can provide. When evaluating, consider how the solution will integrate with your existing security frame work to maintain consistent security policies. Assess whether the network supports a zero-trust architecture and determine if private 5G can operate within your current firewall environment or if new configurations are needed. Finally, consider how well the solution enables IT/OT convergence while maintaining necessary air-gapping to protect sensitive operational assets from potential cyber threats.
5. Devices and applications
A successful private 5G deployment requires a clear understanding of the devices and applications it will support. Identify which devices need to connect - are they rugged handhelds, sensors, cameras or autonomous equipment? Then consider the applications running on these devices - like real-time monitoring, video analytics and safety systems - each will have unique demands for latency, bandwidth and reliability.
Other considerations include connecting legacy equipment without cellular support, managing SIM/eSIM provisioning at scale, and ensuring QoS prioritises critical applications.
6. Success criteria
Success will come down to both network performance and operational impact. Key metrics to track include uptime, latency, coverage, device throughput and energy efficiency and non-technical metrics like production efficiency and safety.
7. Total Cost of Ownership(TCO)
Finally, it’s important to look beyond upfront costs and consider the total cost of ownership (TCO). This includes expenses related to infrastructure - think radios, core network components and the network operations platform. There’s also installation, cabling and any additional routing or security infrastructure to be aware of. Ongoing costs like network management, software licensing and recurring fees should also be factored in to get a clear picture of the investment over the coming years.
