HIMA X-CPU 01 – Trusted SIL 3 Certified Controller in Oil, Gas & Power Plants

Description

Application Scenarios

In a North Sea offshore platform, an unexpected pressure surge in a separator vessel triggered a cascade of alarms. The facility’s legacy ESD system responded sluggishly due to single-channel architecture, risking a potential hydrocarbon release. After upgrading to a HIMA H51q system powered by dual HIMA X-CPU 01 modules, the platform achieved true 1oo2D (one-out-of-two with diagnostics) redundancy. During a subsequent overpressure event, the X-CPU 01 units detected the anomaly within 12 milliseconds, executed the shutdown sequence flawlessly, and isolated the affected section—preventing environmental incident and saving millions in potential downtime.

This real-world case underscores how the HIMA X-CPU 01 transforms theoretical safety into operational reality: delivering not just compliance with IEC 61508/61511. but actionable protection when seconds count.

Technical Principles and Innovative Values

Innovation Point 1: True 1oo2D Architecture

Unlike simple dual-redundant CPUs, the HIMA X-CPU 01 implements a 1oo2D design where two independent processors execute identical safety logic and continuously compare results via a dedicated diagnostic channel. If a discrepancy is found—even from a single-bit memory error—the system initiates a safe state. This architecture delivers both high safety (SIL 3) and high availability, minimizing nuisance trips.

Innovation Point 2: Deterministic Real-Time Execution

The X-CPU 01 runs on a proprietary real-time operating system optimized for safety-critical tasks. With cycle times down to 10 ms, it ensures rapid response to hazardous conditions. All I/O updates, logic evaluation, and communication occur within strictly defined time windows—eliminating jitter that could compromise safety in fast-moving processes like turbine overspeed protection.

Innovation Point 3: Comprehensive Self-Diagnostics

Every HIMA X-CPU 01 performs >99% diagnostic coverage, including memory ECC checks, watchdog timers, voltage monitoring, and processor core health verification. Diagnostic data is logged and accessible via HIMA’s Safe Engineering Tool (SET), enabling predictive maintenance and simplifying SIL verification audits.

Innovation Point 4: Secure Engineering & Cyber Resilience

While the safety bus (HSB) is physically isolated, the engineering Ethernet port supports secure firmware updates and configuration uploads with authentication. The module adheres to IEC 62443 principles, ensuring that safety functions remain uncompromised even in networked environments.

Application Cases and Industry Value

Case Study: LNG Terminal Emergency Shutdown

At a major liquefied natural gas (LNG) export terminal in Southeast Asia, the HIMA X-CPU 01 was deployed as part of a full-site ESD upgrade. The system monitors over 500 critical points—including cryogenic valve positions, tank levels, and fire/gas detectors. During commissioning, a simulated leak triggered a full plant shutdown. The X-CPU 01-based system completed the sequence in 18 ms, safely isolating all feed lines and venting excess pressure. Plant managers reported a 40% reduction in spurious trips compared to their previous system, directly improving operational uptime while enhancing safety.

Case Study: Chemical Reactor Protection

In a European fine chemicals plant, runaway reactions posed a constant risk. The HIMA X-CPU 01 now controls a dedicated SIS that monitors temperature, pressure, and agitator speed. Its fast cycle time allows early intervention—activating cooling jackets or quench agents before thresholds are breached. Since installation, zero thermal incidents have occurred, and the system passed its first TÜV audit with zero non-conformities.

Related Product Combination Solutions

To maximize the performance and reliability of your safety system, the HIMA X-CPU 01 is typically deployed alongside these complementary HIMA modules:

HIMA X-FAN 01: Redundant fan module for active cooling in high-ambient installations.

HIMA X-PWR 01: Dual-redundant power supply unit ensuring uninterrupted operation during grid fluctuations.

HIMA F-DI 01: Fail-safe digital input module for connecting emergency pushbuttons, limit switches, and solenoid valves.

HIMA F-DO 01: Safe digital output module for actuating shutdown valves and motor starters.

HIMA F-AI 01: Analog input module for monitoring critical process variables like pressure, temperature, and flow.

HIMA X-BUS 01: Safety backplane that interconnects all X-CPU 01 and I/O modules via the HSB (HIMA Safety Bus).

HIMA H51q Rack: The standardized chassis housing up to 14 modules, including redundant X-CPU 01 pairs.

Installation, Maintenance, and Full-Cycle Support

Installing the HIMA X-CPU 01 requires adherence to strict safety lifecycle procedures. Modules are mounted in the H51q rack with proper grounding and shielded cabling to the I/O subsystems. Redundant configurations demand precise synchronization during initial power-up—achieved automatically via the HSB—but must be verified using HIMA’s SET software before commissioning. Environmental conditions (temperature, humidity, EMC) must comply with IEC 61511 Annex F to maintain certification validity.

Maintenance of the HIMA X-CPU 01 is streamlined through continuous self-monitoring. The front-panel LEDs provide immediate status indication (RUN, ERROR, REDUNDANCY OK), while detailed diagnostics are accessible remotely. In the rare event of a fault, the module supports hot swapping in redundant setups—allowing replacement without process interruption. Firmware updates are performed securely via encrypted engineering sessions, preserving functional safety integrity throughout the update.

As a trusted partner for critical infrastructure, we ensure every HIMA X-CPU 01 is sourced as new-in-box or factory-refurbished with full traceability. Each unit undergoes functional validation, including redundancy sync and diagnostic coverage tests, before shipment. We provide 24-month warranty, technical consultation for SIL verification, and global logistics support to keep your safety systems always ready.

Don’t compromise on safety. Contact us today for genuine, testedHIMA X-CPU 01modules and expert support to safeguard your operations.