After a decade of operating in the harsh and challenging environments of ATEX Zone 1 production areas, our client based in the Northeast of England faced an all too familiar challenge: aging HMI infrastructure, obsolete technology, tightening budgets and critical deadline dates. They needed a reliable, cost-effective upgrade solution—one that could withstand the challenging conditions while unlocking new levels of functionality, efficiency, and safety.
Their trusted GECMA CHALLENGER Terminals, once reliable, were becoming increasingly difficult to support.
The Challenge
- Legacy terminals many years past end-of-life status
- Increasing maintenance costs and downtime risks
- Strict ATEX compliance requirements limiting upgrade options
- Distances to safe area exceeding the capabilities of modern copper communications.
- Looking to avoid invasive mechanical mods in mounting new equipment
- Looking to leverage existing cable runs where possible
The Solution
Working closely with the client to implement a cost-effective and reliable upgrade path.
Transitioning from the outdated CHALLENGER terminals to the latest generation of GECMA Workstation solutions.
This next-gen solution delivered
- Enhanced capabilities and supported technology
- Increase Screen from 19” to 22” and upgrade to HD resolution for optimal UX
- Full ATEX and IECEx certification for Zone 1 environments
- Seamless integration into their existing infrastructure
- Multi-mode Fibre communications, capable of distances of up to 1000m
- Leverage existing power cables
Implementation
Our approach focused on minimal disruption and cost – maximum impact:
- Detailed on-site assessment to map current infrastructure
- A coordinated upgrade plan and delivery schedule to avoid downtime
- Ongoing support to ensure a smooth transition
Impact
- Improved system reliability
- Reduced total cost of ownership
- Enhanced operator efficiency and safety
- Improved User Experience
- Future-ready infrastructure aligned with digital transformation goals
Facing similar challenges with legacy systems in hazardous areas?
Let’s talk. We’re here to help you future-proof your operations.