Nonstop safety for everyone who thinks ahead

High plant productivity thanks to intelligent  safety solutions 

Do you wish safety solutions that neither cause unscheduled  shutdowns and nor need to stop the plants for maintenance  works, changes or extensions? 

Do you think that safety systems  are neither supposed to limit the productivity of a system nor  to cause excessive and unnecessary investments? 

Then you need intelligent safety solutions that both ensure  maximized safety and availability, and increase plant productivity. 

These safety solutions can, for example: 

ƒ Reduce lifecycle costs 

ƒ Reduce investment costs 

ƒ Minimize planning and operating failures 

ƒ Reduce costs due to operating stops

HIMax will meet your expectations: 

ƒ No compromises in safety! 

ƒ No compromises in productivity

HIMA. Safety. Nonstop. 

It’s a philosophy more than 100 years in the making. It’s  built on HIMA’s singular focus on safety and is proven by decades of technology breakthroughs. It represents our  commitment to providing maximum safety and uninterrupted plant operations. Our goal isn’t just to design the world’s  best safety systems. It’s to help keep your business safe and  running. No shutdowns. No failures. Maximum uptime.  Maximum profitability.

Nonstop SIL 3 safety for the process industry 

HIMax solutions are used in the most various SIL 3 applications.  For instance: 

ƒ Steam crackers 

ƒ Polyethylene, polypropylene and PVC production plants 

ƒ Fertilizer plants 

ƒ Onshore/offshore facilities, platforms and FPSO 

ƒ Pipelines 

ƒ Tank farms and gas containers 

ƒ Loading stations 

ƒ Refineries 

ƒ Combustion and power plants 

ƒ Turbines and compressors 

ƒ Batch operations 

ƒ Others

Thinking ahead within the lifecycle 

With HIMax, HIMA provides you not only the world's leading  nonstop safety system, but also supports you simultaneously  with qualified, sophisticated and coordinated services for all  phases of the safety lifecycle.

Major solutions 

High-availability solutions with HIMax guarantee safe  and uninterrupted operation for every safety-critical  process in your facility. Emergency shutdown systems  (ESD), Fire & Gas systems or high-integrity pressure  protection systems (HIPPS) are but a few typical  applications. Additionally, HIMax is the core element of the new complete solutions developed for the process industry: ƒ FlexSILon TMC for turbines and compressors ƒ FlexSILon BCS for burner control and boiler  protection ƒ FlexSILon PMC for the management of gas and  liquid fuel pipelines HIMax provides the flexibility you need. Because  HIMax offers safe SIL and standard NonSIL modules.  In case of a safety related revalidation of a machine  you are able to substitude NonSIL for SIL modules  quickly and easily afterwards.

Profitability on top 

ƒ Buy only what you need. HIMax adapts to meet virtually  any application requirement. 

ƒ HIMax can be your single platform for all I/O count,  response time and fault-tolerance requirements, as well  as centralized or distributed applications. 

ƒ Save engineering time and costs using a flexible, intuitive  and easily adaptable platform. ƒ HIMax integrates with any DCS that you use today or in  the future.  

ƒ HIMax offers virtually unlimited expansion – hardware and  software changes can be performed on demand, without  interruption, for the full life cycle. Cabinet size is minimised because there's no need to allocate slots for spares. 

ƒ Benefit from HIMax’s unprecedented performance and  system flexibility by integrating more I/Os or greater  application complexity per system.  

ƒ HIMax is a cost-effective solution with different rack sizes  to match your physical space requirements. 

ƒ No hidden software costs. With a SILworX® software license,  you get a single intuitive software tool for all tasks.

User-friendly features 

How HIMax makes it easier for the user: 

ƒ Automatic module detection 

ƒ Fully integrated and protected power distribution eliminates  the need for external wiring 

ƒ Fast implementation via HIMA SILworX, a user-friendly  software tool with an intuitive interface, self-documentation  and embedded version control 

ƒ Accelerate start-up by building-up and testing the hardware  configuration without the application program (Loop  check mode)  

ƒ Comprehensive diagnostics, automatic recording of  500/2,500 diagnostic entries on each module 

ƒ Built-in user management for project- and system access  

ƒ HART protocol support simplifies asset management  solutions 

ƒ Multitasking affords interference free, parallel processing  of applications 

ƒ Integrated version comparison provides exact and  graphical traceability of changes

Greater efficiency through simulation 

The X-OTS HIMax Safety Simulator adds the aspects of  safety to the classical OTS (Operator Training System).  X-OTS is based on HIMA’s programming tool SILworX  and a corresponding number of extended soft PLCs. Each  HIMax controller will be simulated by one soft PLC. Up to 10  soft PLCs can be run on one PC (performance depending). 

ƒ Application software can be checked in real  scenarios prior to commissioning, leading to shorter  commissioning times 

ƒ Shorter commissioning times lead to an earlier  plant start up 

ƒ Application software can already be optimized prior  to start up, leading to a higher plant efficiency  already at start-up (instead of optimizing in the  running plant) 

ƒ Avoiding of plant trips by improved behaviour of  operators

Sophisticated mechanics 

For the best possible handling: 

ƒ Fully enclosed modules 

ƒ Replace module without disturbing I/O or power wiring  

ƒ All racks are panel mountable; the 15 slot is also available  for 19-inch rack installation 

ƒ Fully integrated and protected power distribution 

ƒ Two different field wiring options, i.e., direct wiring using  terminal strips or system cables on field termination  assemblies

Requirement based rack sizes 

ƒ Three available rack sizes: 10, 15 and 18 slots 

ƒ In case of using X-CPU 31, up to 4 slots can be used with  additional I/O or COM modules

Performance pays off 

HIMax is the most powerful safety platform ever invented.  Its unprecedented performance is based on high-performance components and smart system architectures. 

ƒ Cycle time of 50 ms with 1,000 I/Os  (split 50% analog/digital) 

ƒ Unlimited complex calculations 

ƒ Impact of calculation of 1,000 PIDs on cycle time: 10 ms 

ƒ Signal conditioning directly on I/O modules with no impact on CPU performance 

ƒ Up to 2,048 I/Os per cabinet 

ƒ A system with up to 12,800 I/Os 

ƒ Up to 200 I/Os in up to 16 racks per system  

ƒ 250 systems per network 

ƒ Multitasking: Set fixed scan times for dedicated  applications 

ƒ Sequence of event (SOE), 1 ms resolution quality 

Online expandability 

In case of expanding the update is written to a second memory  area, after which the system switches seamlessly to the update. This method of intelligent memory management ensures that  the controller is always operational regardless of whether it is mono or redundant. There is no limit to the number of times  a program can be reloaded during operation. Even operating  systems can be updated during operation. I/O modules, their associated connector boards, base plates  and remote components can also be added during operation.  The same applies to new base plates and remote components.  All can be modified without having to stop the plant. Online  expandability of hardware and software guarantees maximum  flexibility during the entire life cycle.

Optimizing plant efficiency, e.g., using C code 

New process optimization potential is opened up by integrating  mathematical and statistical models for dynamic process control  or by more frequent sampling of process values within the safety  system. Critical processes with continuously changing process  variable values can thus be run closer to the limit ranges. For  example: If the dynamic process value temperature in an  ethylene cracker can be kept 1 to 2 degree closer to the critical  limit, plant productivity increases considerably, while full process  safety and availability are maintained. 

Self education  

If the system diagnoses an internal fault, the module involved  can be replaced quickly during operation. Only a few moves  are required. If a processor module is swapped, the new module is automatically brought up to date with the currently operative modules.  The parameter setting and the user program are imported from the functional processor module and then loaded. 

“Self-education” has other benefits for the user:

ƒ Your inventory of spare parts will be smaller 

ƒ You do not have to search for correct software versions 

ƒ When replacing a processor module, you do not have to  connect a computer, which eliminates subsequent potential  fault causes.