Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues

Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

Use of WiFi-Based Intercom Devices to Eliminate

Radio Lease Cost and Interference Issues
L. Osabel, M. Al-Ghanem, N. Al-Jaraan, M. Al-Somali, 2013
Building Maintenance Section, Technical Services Department MSD
SABIC Saudi Iron and Steel Company (Hadeed), Jubail, Kingdom of Saudi Arabia
Abstract
The intercom devices in Hadeed cranes use fixed radio transceivers operating in
maritime navigation frequency range of 410 to 430 Megahertz. This frequency is
regulated by the government and must be leased and licensed for legal use. There are
16 licensed frequencies for the handheld radio devices of ISD which costs SAR 560,000
annually (ISD, 2010). However, there are 39 cranes that use the maritime frequency
without licenses. The amplitude or signal strength is deliberately attenuated so that it will
only cover a very small area within the distance coverage of the crane radio system and
not disturb the organizations that might be licensed to use it. These radio frequencies
often had interferences with the other organizations such as the military and commercial
radio stations within range, causing legal issues and other inconveniences in
communications.
To eliminate lease cost and radio interference, the use of the WiFi is proposed in
replacement to maritime radio. This type of digital communications protocol will make
the intercom system more adaptable to open-ended communications platform which is
on the rise nowadays.
WiFi-based intercom devices are not normally available commercially. But with the
proper utilization and combination of existing technology, the wireless intercom station
will become the most practical communications tool in the plant.
Background
The intercom system in Hadeed is a hybrid of analog and digital circuits from Industronic
and Neumann (brands). They employ trunk technology similar to a telephone system,
but uses only one-way broadcast protocol to transmit voice data over a dedicated
trunked network. Unlike the telephone where conversation operates both ways within a

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

communication line, the intercom allows only the transmission of voice conversation one
direction at a time. A dedicated button or other forms of triggering mechanism allows the
user to dial out or call a specific station and then directly initiate voice transmission
immediately. Figure 1 shows the scenario of how an intercom station communicates to
other stations. Figure 2 shows the operation of a telephone similar and in contrast to the
intercom.

Figure 1-1 Intercom Station A

Figure 1-2 Intercom Station B

In Figure1-1, operator pushes a dedicated button at Intercom Station A to dial-out (or

call) Intercom Station B. In Figure 1-2, Intercom Station B immediately hears the voice
transmission broadcasted from Intercom Station A. While Intercom Station A is engaged
to broadcast the voice message, Intercom Station B is only allowed to receive and
listen. Thus, voice data is transmitted one-way (half-duplex).

Figure 2-1 Telephone User A

Figure 2-2 Telephone User B

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

In Figure 2-1, Telephone User A initiates a call to Telephone User B. When User B
answers the call, a two-way communication is established where both parties can
transmit voice data both ways (full-duplex).
Operation of a Crane Radio Intercom Station
Intercom stations are connected with each other through a Central Exchange where
transmission and reception of voice data happens over several mediums of passage in
the form of copper or fiber optic cables or wireless (radio frequency). Figure 3 shows the
basic diagram of intercom system connectivity.

Crane
Station 01

Intercom
Station 01
Copper Wire
Intercom
Station 02

Intercom
Station 03

Intercom
Station X

Wireless
Crane
Station 02
Intercom System
Central Exchange
01

Intercom System
Central Exchange
02

Crane
Station 03

Crane
Station Y

Figure 3 Basic Intercom Connectivity Diagram

When Intercom Station (IS) 01 attempts to call IS-02, voice data is transmitted to the
Central Exchange (CE) and then sent to IS-02 through the copper cable. In similar
manner, when it attempts to call Crane Station (CS) 01, voice data is sent to the CE
before it is sent to CS-01 through radio instead of copper wire.
The operation of the intercom stations used in cranes is similar to the actual operation of
a walkie-talkie (amateur radio) device. It also uses a PTT (push-to-talk) button to
transmit the voice data over a dedicated radio frequency bandwidth which is leased
from the government. Figure 4 shows the basic operation of a crane intercom station
attempting to call other intercom stations.

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

As Intercom (Ground) Station A calls for Crane (Radio) Station X, the Central
Exchange processes the requests by sending it through the Radio Unit for CS-X. Thus,
in a traditional intercom-to-intercom setup, the Radio Unit replaces the intercom station.
The Radio Unit transforms the digital signal coming from the Central Exchange into
analog radio waveform to be received by the Radio Unit of the corresponding crane
station.

Intercom
Station (IS) A

Intercom
Station (IS) B
Wireless Connection
Radio Frequency, MHz

Intercom
Central
Exchange 01

Radio Unit
TX 422.0250
RX 412.0250

Copper Wire

.
Copper Wire

Radio Unit
For CS-X

Crane
Station (CS) X

Hand-Held
Radio Device
RX/TX 412 MHz

Radio Unit
For CS-Y
Radio Unit
For CS-Z

Crane
Station Y
Radio Unit
TX 422.0500
RX 412.0500

Crane
Station Z
Radio Unit
TX 422.8750
RX 412.8750

Figure 4 Basic Operation of a Crane Radio Intercom Station

Note that the receive frequency for the crane stations are primarily set to 412 MHz. But
in order for the system to distinguish which radio station can receive, it uses side band
frequency in the Kilo Hertz range. Thus, from Figure 4, Radio Unit for CS-X must
transmit the voice data at 412.025 MHz (412 MHz + 25 KHz).
All the voice data transmitted by all the radio units at the central exchange is set for a
single frequency (such as 412 MHz in Figure 4). Thus, by the use of a handheld receiver
(walkie-talkie), all the voice data can be intercepted at this frequency. Since hand-held
devices (or any other radio receivers) can be configured to operate at a channel in the
MHz range without considering the sidebands which is in KHz range, it is possible to
hear all the exchange of communications from all crane and ground stations at the

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

same. And at similarly, the handheld radio can transmit the same message to all cranes
that are within radio range.
Problem Scope
Lease Cost of Radio Frequency Usage
In Saudi Arabia, equipment operating in radio frequency between 405 to 526 MHz is
usually allocated for maritime mobile communications for navigation (CITC, 2003). Thus,
the usage of this frequency channel requires the stringent approval from the Saudi
government through the Communication and Information Technology Commission
(CITC) to acquire a license. And in Hadeed, there are a total of 16 licensed channels
with a lease cost of SAR 560,000 per year (ISD, 2010). A single channel corresponds to
a main carrier frequency in the MHz range and another sideband frequency in the KHz
range which is used to distinguish the identity for each crane. These frequency channels
are used by the handheld radios from ISD. Table 1 shows the 16 licensed channels
allocated for Hadeed. Thus, we can assume that for each frequency channel, SAR
35,000 may be spent annually.

SN

Transmit Frequency, MHz

Receive Frequency, MHz

01
02
03
04
05
06
07
08

422.0250
422.0500
422.8750
422.8500
427.4125
427.4375
427.4750
427.6750

412.0250
412.0500
412.0875
412.8500
417.4125
417.4375
417.4750
417.6750

Table 1 Licensed Frequency Channels allocated for ISD Radios

Unlicensed Radio Channels
There are 39 cranes in Hadeed that use the maritime frequency without licenses. They
often had interference with other organizations operating in the same frequency. But
since the signal strength (dB) in Hadeed cranes are attenuated (or reduced) they
usually do not disturb the other organizations. However, those organizations that are

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

licensed to use the same frequency have been transmitting their signal to our receivers.
Table 2 shows the unlicensed frequencies that are being used by Hadeed cranes. And if
Hadeed were to lease and license all of these frequency channels, it would cost around
SAR 1,365,000 annually.

SN

Frequency

Plant Name

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

412.450
413.025
414.025
417.475
424.120
427.475
440.125
440.150
440.175
440.200
440.450
440.450
440.850
440.925
440.950
441.250
442.050
440.088
440.100
441.025
441.725
440.225
440.250
440.275
440.300
440.325
440.350
440.375
440.400
440.425
460.250
460.350
460.650
414.250
415.025
440.0825
440.0875
440,950
461.440

DR-A&B
SPLP
SPLP
SPLP
Billet Bay
SPLP
SPFP/HSM
SPFP
SPFP
SPFP
SPFP
SPFP
SPFP
SPFP
SPFP
SPFP
SPFP
DR-E
DR-E
HSM
HSM
HSM
HSM
HSM
HSM
HSM
CMC
CMC
CMC
CMC
RMLP
RMLP
RMLP
SPFP
SPFP
SPFP
SPFP
SPFP
RMLP

Crane Name / Location

Crane #1 & 2
Crane # 04 & 14
Crane # 06
Crane # 40
Crane # , 485 , 467 , 465
Crane# 50
Crane # SE 11 CP, Mill HSM
Crane # SE 11 - CP2
Crane # CB 441 -CB 1
Crane # CB 450 - CB1
Crane # SE 7612 -CB
Crane # SE 21 -CB1
Tundish Crane # CB -7604 -CB
Crane # SE 21 -CB1 + KK36-CB
Crane # SE 21 -CB2 + KK39- CB1
Tundish Crane # CB 201 - CB
Crane # CB 7644-CB
Stacker # 125 F 01 A & Mobile HOP A
Stacker # 125 F 01 B & Mobile HOP B
Crane# WC21 .7601 - CB1 + CB2
Crane # WC 21.7602 - CB
East Crane ( WC 21.7661-CB)
West Crane (WB 32-CB1 +CB2)
Crane # WB33 - CB1 + CB2
Crane # WB34 - CB + WB 61
Crane # CB7641-CB + CB7642 CB
KK16-CB1 -CB2
KK22-CB +CB2
KK33-CB + KK24-CB2
KK24-CB1 + KK39-CB2
Crane # CF04 , CF05 , CF06
Crane # CB74 , CB74 , CB76
Crane # 484 + 469
caster FP
caster FP
Tundish Crane
Teeming Crane 3
SE 21 CB2
Crane # 470 + 468

Table 2 Unlicensed Radio Frequencies used in Hadeed Cranes

Radio Interference Issues

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

There are 39 cranes in Hadeed that employ radio intercom stations. All of them use
maritime radio frequency to communicate to ground intercom stations and, most
importantly, to control rooms. Since there are only a few channels being used in Hadeed
in order to minimize interference from very active maritime frequencies, these known
rare and idle channels are pre-selected for the different crane stations that are at least a
few hundred meters away or distant enough to avoid radio interference. For this to be
feasible, the signal amplitude has to be attenuated. Figure 5 shows the diagram of how
attenuation is practically done to avoid radio interference between radio devices in
Hadeed operating in the same frequency.

Figure 5.1 Carrier Waveform (CW) = 422 MHz

Amplitude/Distance = 30dB/100meters & 15dB/50meters (Attenuated by 50%)

Figure 5.2 Voice Waveform (VW) = 20 Hz 20 KHz

Figure 5.3 Output Frequency = Modulated Signal (CW + VW)

Figure 5 Carrier & Voice Waveform of a Radio Signal

Assuming that at amplitude 30 dB, the distance covered by the signal is up to 100
meters. This directly means that another crane within 100 meters cannot use the same
frequency channels. Otherwise, interference occurs. Interference is the unwanted
overlapping of signals from difference radio equipment. Ideally, we do not want a nearby
crane station to be hearing commands from a ground intercom station whose
instructions or communication are unrelated or irrelevant to the operations being
conducted at the moment. It would be disastrous for a crane operator to hear the wrong
instructions from another control room. Thus, to compensate for unwanted
interferences, signal attenuation is being done (Figure 5.1) when it is really necessary to

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

use the same range of frequencies. This is usually the case where more crane stations
are operating very near at certain locations within the plant. However, despite
adjustments and signal compensation techniques to minimize interferences, other
unknown variables persists that made the radio intercom system prone to errors and
drawbacks due to the repeated use of the same band of radio frequency over a small
area in Hadeed. Theoretically, radio frequency transmission is constant over a vacuum.
But with other parameters involved such as temperature, humidity, blockage, and
crosstalk, radio may not be as stable and reliable due to its analog nature.
Crosstalk Due to Atmospheric Changes
Crosstalk is defined as interference due to a presence of another data (e.g. voice)
occurring in the same frequency or this is also known as co-channel interference. It may
also occur as adjacent channel interference where poor frequency control is occurring.
Either ways, crosstalk is unwanted in any radio operation. It has been theorized that
changes in atmospheric or weather conditions can alter the ranges of the radio signals
being propagated. As observed locally in the eastern province of Saudi Arabia, during
the hot season, radio signals have the tendency to cause interferences. Hot season is
usually associated with high barometric pressure in the atmosphere when humidity
peeks. And during periods of uniquely high-pressure weather, radio signals (especially
the VHF) (Cox, 2003) which would normally exit through the atmosphere could be
reflected back to the ground causing interference to other radio transmitters in the areas
affected by the increased range of the distant transmitter (Wikipedia, 2013). Simply put,
the increased range of some radio transmission is being received by other radio
receivers in Hadeed, causing confusion at the receivers end, whether or not the voice
data is intended for the recipient hearing the same message. Figure 6 shows the
crosstalk phenomenon during high barometric pressure weather condition.
In 2008, an incident was reported that our radio signal had reached as far as Bahrain
Causeway and interfered with some military frequencies in the Eastern Province area.
An investigation was being made and some conclusions were drawn. It was found out
that at certain times during the year, the radio signals generated in Hadeed were altered
to some degree causing interference with other existing channels due to the changes in
atmospheric parameters such as temperature and pressure.

Normal Pressure Weather,

Radio escapes into the Troposphere

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

During Very High Pressure Weather,

Radio bounces back to over long distances
During High Pressure Weather,
Radio bounces back to outer range

Normal
Range

Intended
Receiver

Unintended
Receiver

Other radio on same

frequency channel
outside of Hadeed

Other radio on same frequency

channel within Hadeed

Figure 6 Crosstalk or Co-Channel Interference due to Atmospheric Changes

In Figure 6, radio transmission during a very high barometric pressure causes the signal
to bounce back from the second atmospheric layer. Dense air causes the frequency to
shift and being received by distant radio receivers. The receiving end could be a military
facility or an AM/FM broadcasting organization which is in the KHz frequency range,
considering that the frequency used in Hadeed also uses sidebands in the KHz range.
Innovation
To eliminate the need for leasing unnecessary regulated frequency channel from the
government, a proposal was raised up to establish a frequency band that is free to use
without licenses, dedicated, secure, and stable enough to accommodate considerable
distance of wireless coverage. And upon evaluation of the criteria requirement of a
wireless system, the best feasible and dynamic frequency that is free, dedicated, secure
and stable is the Wi-Fi (Wireless Fidelity or WLAN Wireless Local Area Network). The
WIFI operates in a 2.4 GHz frequency band, which is a lot higher than the traditional
leased radio band for maritime navigation which is around the 405 to 526 MHz band.
This makes it convenient, in theory, for data transmission, as well as voice. It is also a
stable, constant and low power consuming wireless system since it is digital, unlike the
current maritime radio used in Hadeed cranes which is analog. Digital wireless systems
differ than that of analog systems in a way that it transmits data and consumes power.
The protocol used is also far different from each other.
In digital transmission, voice data (analog) is transmitted digitally by amplitudefrequency conversion directly at the machine level Thus, for the wireless transmission to
fully benefit the digital system it has to be compatible with already existing technology
such as voice over IP. Voice over IP (VoIP) is widely used in telephony nowadays. It

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

uses the local area network (LAN) architecture to transmit voice data. And for the crane
intercoms to benefit in this technology, it has to use the same existing LAN architecture
that is already present in Hadeed. Figure 8 illustrates how the crane intercom devices
can dynamically use the existing LAN in Hadeed, virtually connecting to other
communications devices (such as IP or digital telephone, wireless (DECT) phones,
workstation PCs and other devices) within the same network, and thereby, eliminating
lease cost and radio interferences, since these devices utilizes only IP bandwidth.

Crane
Station (CS) X

Intercom
Station (IS) A

WiFi-Enabled Intercom

Wi-Fi Switch
Intercom
Central Exchange 01

IP Gateway 10.12.24.1

IP 10.12.24.65

Wi-Fi Hotspot for Crane Intercom, IP Phone and Data, (Range: 300
m)
Crane
Frequency Band 2.4GHz

Industronic or Neumann

Station (CS) Y

WiFi-Enabled Intercom
IP 10.12.24.66

SABIC-Hadeed Network
Crane
Station (CS) Z

Wireless Phones

WiFi-Enabled Intercom

Telephone System

IP 10.12.24.67

Siemens
HiPath 4000

Work Stations
IP/Digital Phones

Figure 8 Innovative interconnection of the Intercom System with other Devices

Hardware Requirements and Cost Comparison
Traditional hardware components and corresponding cost required to setup an intercom
station in a crane operating in maritime radio band are shown in Table 3. While
hardware components and corresponding cost required setup a WiFi-enabled intercom
station in a crane are shown in Table 4.

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

SN

Component Name

Description

01

Crane Intercom Station

Main intercom device

02

Radio Transceiver

Unit and module for radio transmission

03

Antenna

Antenna coupling and cabling

04

Frequency Lease

Cost estimate

05

Other Accessories

Cost (SAR)

26,000
10,050
3,000
35,000
1,000

Cost Per Maritime Radio Crane Intercom Station

75,050

Table 3 Hardware Components of a Traditional Crane Intercom (Somac, 2013)

SN

Component Name

Description

01

Crane Intercom Station

Main intercom device

02

Antenna

Antenna coupling and cabling

03

Access Point

Unit and module for WiFi (WLAN Switch)

04

Other Accessories
Cost Per WiFi-Enabled Crane Intercom Station

Cost (SAR)

21,235
1,550
11,880
1,000
35,665

Table 4 Hardware Components of a WiFi-Enabled Crane Intercom (Somac, 2013)

As evident in Tables 3 and 4, the cost of setting up a traditional crane radio intercom
station becomes expensive when the frequency is to be licensed compared to a WiFibased intercom station which uses only a free WiFi bandwidth. Besides the lease cost,
traditional crane intercom stations can suffer from interference issues from other radio
devices, as well as cause crosstalk (or co-channel interferences), while advantages of
an IP-based intercom station remained promising as far as connectivity and
upgradability are concerned. It is therefore recommendable to use WiFi-enabled
intercoms in replacement to traditional maritime radio intercoms.

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Use of WiFi-Based Intercom Devices to Eliminate Radio Lease Cost and Interference Issues
Osabel, Ghanem, Jaraan, Somali | Telecom, BM, TSD-MSD | HADEED Technical Innovation Week 2013

References

CITC, 2008. National Frequency Plan of the Kingdom of Saudi Arabia, 2013.
Communications and Information Technology Commission (CITC), KSA. Accessed
on 25-August-2013. Available at: http://www.citc.gov.sa/English/ RulesandSystems/

RegulatoryDocuments
Cox D.C., 2003. Co-Channel Interference Considerations in Frequency Reuse

Small-Coverage-Area Radio Systems. Bell Labs, Holmdel, NJ, USA.

ISD, 2010. Industrial Security Department, Saudi Iron and Steel Company (Hadeed).
Somac, 2013. Hardware Components of Radio Crane Stations: Industronic,
Hardware Components of Wi-Fi Intercom Stations: Neumann. Commercial

Quotation from Saudi Operations and Maintenance Company (SOMAC).

Wikipedia, 2011. Crosstalk (Electronics), 2011. Wikipedia (The Free Encyclopedia).
Accessed on 25-August-2013. Available at: http://en.wikipedia.org/ wiki/
Crosstalk_(electronics)

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