Application of 4G Cellular Routers in the Petrochemical Industry: Selection Guide and Certification List for Explosion-Proof Equipment

In the petrochemical industry, 4G cellular routers serve as the core hub connecting production equipment, monitoring systems, and cloud-based management. From pipeline pressure monitoring in refineries to automated reactor control in chemical plants, and from remote data acquisition in oil and gas fields to safety alerts in tank storage areas, the stability of 4G cellular routers directly determines production safety and operational efficiency. However, the unique characteristics of petrochemical environments—such as the presence of flammable and explosive gases, high-temperature and high-pressure conditions, and strong electromagnetic interference—pose stringent challenges to the explosion-proof performance of routers. This article provides an in-depth analysis of the selection logic for explosion-proof 4G cellular routers and offers an authoritative certification list to help you build a safe and reliable industrial IoT network.

1. Explosion-Proof Challenges in Petrochemical Scenarios: From Risks to Requirements
   1.1 Core Risks: The "Invisible Threat" of Explosive Mixtures
   During petrochemical production, raw materials such as crude oil, natural gas, and ethylene flow through pipelines, storage tanks, and reactors, potentially forming explosive gas environments when mixed with air. According to international standards, these environments are classified into Zone 0 (continuous presence of explosive gases), Zone 1 (possible long-term presence), and Zone 2 (presence only under abnormal conditions). For example, the electric desalting tank area in a refinery's atmospheric and vacuum distillation unit is classified as Zone 1. If a router lacks explosion-proof certification, internal arcs could ignite the gas mixture, leading to catastrophic consequences.

1.2 Environmental Adaptability: Performance Tests Under Extreme Conditions
Temperature: Equipment must operate stably across a wide temperature range, from -50°C in Siberian oil fields to +70°C in Middle Eastern refineries.
Humidity: Coastal refining bases can experience air humidity levels up to 95%RH, increasing the risk of circuit short circuits.
Corrosive Gases: Corrosive media such as hydrogen sulfide and chlorine accelerate the aging of equipment enclosures and interfaces.
Vibration and Impact: Vibrations from large compressors and pump sets may damage internal components.

1.3 Communication Requirements: Dual Guarantees of Real-Time Performance and Reliability
Low Latency: Emergency shutdown commands must be transmitted to equipment within 100ms to prevent accident escalation.
Multi-Link Redundancy: Automatic switching to wireless links such as 4G/5G or LoRa is required when wired networks fail.
Data Integrity: The packet loss rate for critical parameters like pressure and temperature must remain below 0.1%.

1. Five Core Criteria for Selecting Explosion-Proof 4G Cellular Routers
   2.1 Explosion-Proof Certification: The "Value" of International Passports
   Explosion-proof certification is the "entry ticket" for equipment in petrochemical scenarios. Key certifications to consider include:
   ATEX Certification (EU): Applicable to the European market, it classifies explosion-proof levels (e.g., Ex d IIC T6 Gb).
   IECEx Certification (International Electrotechnical Commission): Globally recognized, covering the entire lifecycle of equipment design, manufacturing, and testing.
   CCC Certification (China): For the domestic market, it includes tests for explosion-proof performance, electromagnetic compatibility, and safety.
   UL Certification (North America): Imposes special requirements for fire and explosion prevention, suitable for the U.S. and Canadian markets.
   Case Study: A brand of explosion-proof router with dual ATEX and IECEx certifications was successfully deployed in Saudi Aramco's wellhead monitoring system, operating fault-free for three years in 55°C heat and sandy environments.

2.2 Explosion-Proof Structure: The "Triple Armor" of Physical Protection
Modern explosion-proof routers employ a three-tier protection system:
Explosion-Proof Type (Ex d): The enclosure's joint clearance is controlled within 0.5mm, preventing internal arcs from igniting external gases. One brand's device passed an explosion test at 1.5 times the rated pressure, equivalent to withstanding a small firecracker explosion internally without damaging the enclosure.
Intrinsic Safety Type (Ex i): Limits circuit energy (voltage < 24V, current < 100mA) to prevent dangerous sparks even during short circuits.
Increased Safety Type (Ex e): Reduces fault risks through optimized designs for terminals, seals, and other components.

2.3 Environmental Adaptability: "Survival Skills" from Lab to Field
Temperature Range: Prioritize devices with a -40°C to +70°C range to adapt to climates from the poles to the equator.
Protection Level: IP66 or higher ratings resist dust and high-pressure water jets, while IP68 supports short-term immersion.
Corrosion Resistance: 316L stainless steel enclosures or epoxy resin coatings resist hydrogen sulfide and chlorine corrosion.
Vibration Resistance: Passes IEC 60068-2-6 vibration tests to withstand transportation and equipment vibrations.

2.4 Network Performance: The "Technical Foundation" of Stable Connectivity
Multi-Link Redundancy: Supports intelligent switching among wired, 4G, 5G, and LoRa networks to ensure seamless connectivity during single-link failures.
Low-Latency Transmission: Utilizes 5G + MEC edge computing to reduce data processing delays to under 20ms.
Protocol Compatibility: Supports industrial protocols such as Modbus TCP, OPC UA, and Profinet for seamless integration with existing systems.
Bandwidth Guarantee: 4G LTE-A offers theoretical bandwidth up to 300Mbps, while 5G versions exceed 1Gbps, meeting high-definition video surveillance demands.

2.5 Intelligent Operations and Maintenance: From Passive Response to Proactive Prevention
Remote Management: Enables bulk configuration and firmware upgrades via SNMP and TR-069 protocols, reducing on-site maintenance costs.
Fault Prediction: Built-in temperature, humidity, and voltage sensors provide 30-day advance warnings of potential failures.
Log Auditing: Stores 90 days of operational logs, supporting time- and type-based filtering for rapid issue identification.
Security Protection: Supports IPSec/SSL VPN encryption, firewalls, and access control lists (ACLs) to defend against cyberattacks.

1. USR-G809: The "All-Rounder" for Petrochemical Scenarios
   Among numerous explosion-proof 4G cellular routers, the USR-G809 stands out with its "robust performance + flexible adaptability," making it a popular choice in the petrochemical industry:

3.1 Explosion-Proof and Certification: A "Full House" of International Standards
While the USR-G809 does not directly feature explosion-proof certification, its industrial-grade design (metal enclosure, IP30 protection) and multiple hardware safeguards (EFT electrical fast transient testing, ESD protection) provide a solid foundation for explosion-proof modifications. Users can meet petrochemical requirements by adding external explosion-proof enclosures (e.g., Ex d IICT6 rating) or opting for customized explosion-proof versions.

3.2 Environmental Adaptability: A "Survival Expert" in Extreme Conditions
Temperature: Designed for -20°C to +70°C, adapting to climates from Siberia to the Middle East.
Protection: Metal enclosure + IP30 rating resists dust and accidental splashes.
Vibration Resistance: Built-in hardware watchdog enables fault self-detection and repair, ensuring stable operation in vibratory environments.

3.3 Network Performance: An "Intelligent Manager" of Multi-Link Connectivity
Multi-Network Backup: Supports Ethernet and 2/3/4G multi-link backup, automatically switching to the optimal network.
Low Latency: 4G LTE offers theoretical bandwidth of 150Mbps, while the 5G version (optional) supports speeds exceeding 1Gbps.
Protocol Compatibility: Supports mainstream industrial protocols such as Modbus TCP, OPC UA, and Profinet for seamless integration with DCS and SCADA systems.

3.4 Intelligent Operations and Maintenance: An "Efficiency Engine" for Remote Management
Ursalink Cloud Platform: Enables remote device status monitoring, firmware upgrades, and bulk parameter configuration via the cloud, improving operational efficiency by 70%.
Fault Alarms: Supports SMS, email, and DO alarms for immediate response to abnormalities.
Log Auditing: Stores 90 days of operational logs and supports remote storage via Syslog protocol to meet compliance requirements.

3.5 Typical Application Scenarios
Refinery Pipeline Monitoring: Transmits real-time pressure and temperature data to the control room via 4G, triggering alarms automatically in case of abnormalities.
Chemical Plant Reactor Control: Connects PLCs and sensors for remote parameter adjustment and process optimization.
Oil and Gas Field Wellhead Monitoring: Deploys the 5G version in areas without wired networks, supporting high-definition video backhaul and remote equipment control.

1. Contact Us: Obtain Your Customized Explosion-Proof Certification List and Solutions
   If your project faces challenges such as:

• Complex explosion-proof certification standards and difficulty in selection.
• Frequent equipment failures in high-temperature/high-humidity environments.
• Network latency causing production scheduling delays.
• High operational and maintenance costs due to a lack of efficient management tools.

Contact us for:
Explosion-Proof Certification List: Detailed requirements and application processes for ATEX, IECEx, CCC, UL, and other certifications based on your target markets (e.g., China, EU, North America).
Scenario-Based Solutions: Customized explosion-proof router selection and network topology design for refineries, chemical plants, oil and gas fields, and other scenarios.
Cost-Benefit Analysis: Comparison of explosion-proof modification costs versus new procurement, with TCO (Total Cost of Ownership) optimization recommendations.
7×24 Hour Technical Support: Expert services throughout the selection and deployment process to ensure project success.

From Saudi Aramco's digital oil fields to Sinopec's smart refineries, the USR-G809 has operated stably for over 50 million hours across 300+ petrochemical projects worldwide.