Our Case Studies

Optimizing one of the world's largest refineries

Equipping an area of 16 sq. km (1600 hectares) with telecommunication as well as security and surveillance infrastructure to make it safer and smarter than ever before.


Owned by a global EPC and serving a multitude of customers, it is of paramount importance that one of the world's largest refineries be secure and optimally operational.

We equipped it with state-of-the-art technology for processing, security, surveillance as well as telecommunication.

The Task

Being one of the largest refineries in the world, covering an area of 16 square kilometres (or 1600 hectare), this project was implemented in five packages for utilization by various EPCs.

The five packages include Main Process Units, Support Process Units, Utilities & Offsites, Tank Farms and Marine & Export facilities. Commtel, as the main system integrator of this project for Telecommunication and Security Surveillance Systems, was responsible for project management, design engineering, procurement, manufacturing, system integration, configuration, FAT, IFAT packing, shipment, installation supervision, commissioning and warranty support of all related systems for the entire plant.

The project’s telecommunication and security surveillance system scope comprised of fourteen systems interconnected on Optical Fibre and Radio.

The Challenge

Delivering one of the world’s largest, and most complex, integrated telecom and security projects to a renowned International EPC for building a new world-class refinery comes with its own set of challenges. The stringent deadlines required that all parties involved coordinate and collaborate as one team.

The Solution

We are ever dedicated to serving our customers with unmatched advanced engineering solutions, often revisiting and reinventing our offerings. We pushed the boundaries of ‘customer-first’ by executing the entire project with minimal external guidance.

The scope of the project is broad; covering the complete aspects of telecom and security & surveillance for the Refinery. Therefore, it will have interfaces to all the other packages of the facility as well. Under the project’s scope, multiple systems are proposed to cater to communications and security needs.

The telecommunication system comprises an Ethernet switch-based OFC network. The proposesd network consists of a backbone network connecting the core switches at the CCR, Maintenance Building, and Administration Building. The core locations are connected to the switches of other buildings through optical fibre cable

  1. LAN System with Cisco Core Switches, Access Switches and Network Switches
  2. WLAN System with Wireless Controllers, Wireless Access Points, WLAN Switches
  3. Telephony with IP Exchanges, Hotline, IP telephony with IP and Analog Telephones
  4. TETRA based Trunked Mobile Radio solution consisting of multiple Repeaters, mobile stations, desktop radios, and hand portables
  5. Public Address and General Alarm system (PAGA)
  6. Process Closed Circuit Television (CCTV)  system
  7. Security / Personnel Access System with Access Control Facility and CCTV security cameras
  8. Weather monitoring system with Meteorological sensors
  9. WAN System with DWDM & SDH
  10. Structured Cabling System including Station Termination Outlets, building inside cables, passive components, racks, and supporting hardware
  11. Uninterrupted Power Supply (UPS) for the systems provided with battery backup.
  12. Global Maritime Distress and Safety System ( GMDSS Marine Radio Systems)
  13. Storage Area Network (SAN System)
  14. Perimeter Intrusion Detection System

The Highlights

  • One of the largest refineries in the world.
  • The entire telecom and security surveillance system of the refinery has been designed and supplied by Commtel.
  • Total of 723 equipment cabinets with multiple systems.
  • 239 cameras were set up in our facility for testing., including an Ex-proof dome, and indoor cameras.
  • Equipment sourced from 37 countries
  • Coverage Study conducted for Plant Radio, PAGA, CCTV, and Wireless LAN
  • FAT and IFAT are done on 100% of equipment generating live traffic from end devices and simulating real-life
    site conditions.
  • Design & Engineering done at Commtel facilities in India and the UAE.
  • Procurement, Integration, FAT, and IFAT at Commtel UAE.

The Benefits

Using state-of-the-art technology, we’ve been able to successfully ensure the smooth and optimal operation of functionalities at this plant. This not only benefits the internal operations of the facility but also enhances the performance of the multiple EPCs utilizing its packages.

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