Secure, ATEX-Certified Plant Monitoring & Control at the Field Level          

Solution Overview

Sierra’s Mobile DCS for Zone 1 Hazardous Areas enables plant operators, maintenance engineers, and commissioning teams to securely access live DCS and PLC systems directly from the field — even within ATEX Zone 1 and Class I Division 1 environments.

By integrating ATEX-certified industrial Wi-Fi infrastructure with intrinsically safe mobile HMI devices, Sierra extends the control room into hazardous process areas, delivering real-time visibility, operational control, and diagnostics without compromising safety, cybersecurity, or regulatory compliance.

This solution is engineered for pharmaceutical, chemical, API, biopharma, and energy facilities where operational uptime, validation integrity, and hazardous area compliance are critical.

System Architecture

The solution is designed as a secure, layered industrial network architecture:

1. Plant Control Layer

• SIL2 / SIL3 PLC & DCS systems (Rockwell PlantPAx, Emerson DeltaV, Siemens PCS 7)
• Centralized control room servers and HMI stations
• Integration with process instruments, control valves, and safety systems

2. Secure Connectivity Layer

• ATEX-certified industrial Wi-Fi gateways for Zone 1 deployment
• Encrypted communication (WPA2/WPA3, VPN tunneling, firewall segmentation)
• Network segregation between control, safety, and enterprise layers

3. Field Mobility Layer

• ATEX / Class I Div 1 intrinsically safe mobile tablets
• Mobile HMI access to live process graphics, alarms, trends, and diagnostics
• Role-based authentication and user access control

 

Key Functional Capabilities

Real-Time Process Visibility

Operators can view live DCS graphics, process values, alarms, and trends directly from the field, enabling faster decision-making and immediate validation of process conditions at the equipment level.

Secure Remote Control (Role-Based)

Authorized personnel can perform limited and controlled operations such as valve actuation, loop testing, and setpoint verification without returning to the control room.

Commissioning & Loop Checks

Engineering teams can perform loop checks, I/O validation, and functional testing directly at the field device while viewing live DCS feedback, accelerating project commissioning and reducing manpower requirements.

Business & Operational Benefits

• Reduced Downtime: Faster fault diagnosis and field-level response
• Improved Safety: Minimizes unnecessary movement between hazardous areas and control rooms
• Higher Productivity: Accelerates commissioning, maintenance, and validation activities
• Audit Readiness: Strengthens compliance with pharmaceutical and regulatory requirements
• Operational Agility: Enables mobile, digital workflows in hazardous environments