AUDE STD 01 - Rockwell - PLC Programming Standard - Rel 2.0

Internal Distribution:
Tenaris DEEN, AUDE
External Distribution:
Tenaris USA Automation
AUDE STD 01
Tenaris DEEN – PLC Programming Standard for Rockwell PLC
AUDE
Release: 2.0
Date:
07-11-11
Created by:
AUDE
Approved by:
Saporiti Claudio
Villalonga Marcelo
Tenaris DEEN Automation AUDE STD 01 Revision: 2.0
PLC Programming Standard
INDICE
1 DOCUMENT OBJECTIVE .................................................................................... 4
2 PLC PROGRAMMING STANDARDS ................................................................... 4

2.1 General Principles .............................................................................................................. 4
2.2 Safety.................................................................................................................................. 4
3 PLANT STRUCTURE AND OPERATING MODES................................................. 5

3.1 Area and zone.................................................................................................................... 5
3.2 Operating Modes............................................................................................................... 6
3.2.1 Automatic............................................................................................................................ 6
3.2.2 Semiautomatic .................................................................................................................... 7
3.2.3 Manual ................................................................................................................................ 7
3.2.4 Blocked ................................................................................................................................ 7
3.3 Local-Remote command enable ....................................................................................... 8
4 PULPIT: GENERAL CONDITIONS........................................................................ 8

4.1 Traditional pulpits ............................................................................................................. 8
4.2 Programmable panels (Panel View) ................................................................................. 9
5 LOGICAL STRUCTURE OF A SEQUENCER ....................................................... 10

5.1 Transitions........................................................................................................................ 11
5.1.1 Initial conditions (automatic and semiautomatic cycle)................................................ 11
5.1.2 Start Cycle Movement conditions ................................................................................... 12
5.1.3 Actions............................................................................................................................... 12
5.1.4 Block .................................................................................................................................. 12
5.1.5 Cycle_End .......................................................................................................................... 13
5.1.6 Fault................................................................................................................................... 13
5.1.7 Change from automatic or semiautomatic to manual mode......................................... 13
5.1.8 Hold ................................................................................................................................... 13
5.1.9 Emergency stop ................................................................................................................ 13
5.2 Steps of the sequencer.................................................................................................... 14
5.2.1 Step 1 – Waiting AUTOMATIC Start ................................................................................ 14
5.2.2 Step 2 – In AUTOMATIC Cycle.......................................................................................... 14
5.2.3 Step 3 ................................................................................................................................ 14
5.2.4 Step 4 to 26-42-58 – In Cycle ............................................................................................ 14
5.2.5 Step 31-47-63 – Block Mode............................................................................................. 14
5.2.6 Step 28-44-60 – Cycle End ................................................................................................ 15
5.2.7 Step 29-45-61 - Fault......................................................................................................... 15
5.2.8 Step 30-46-62 – Manual mode ......................................................................................... 15
5.2.9 Step 27-43-59 – Hold. ....................................................................................................... 15
5.2.10 Step 32-48-64 - Emergency.............................................................................................. 15
5.3 Sub-sequencers................................................................................................................ 15
6 PROGRAM DISTRIBUTION............................................................................... 17
6.1 Fault Routine.................................................................................................................... 18
6.2 Power Up Routine ........................................................................................................... 18
2/31
6.3 Main Task ......................................................................................................................... 18

6.3.1 Inputs Program ................................................................................................................. 18
6.3.2 Main Program ................................................................................................................... 18
6.3.3 Services.............................................................................................................................. 19
6.3.4 Sequencers ........................................................................................................................ 19
6.3.5 Outputs Program .............................................................................................................. 19
7 SEQUENTIAL FUNCTION CHARTS (SFC) OF THE PROGRAM .......................... 20

7.1 Standard for the implementation of the sequencer .................................................... 20
8 DIAGNOSIS ORGANIZATION........................................................................... 21
8.1 Standard for the diagnosis implementation ................................................................. 21
8.2 Standard diagnosis information .................................................................................... 22
9 DIAGNOSIS PROGRAMMING .......................................................................... 22

9.1 Alarms............................................................................................................................... 22
9.1.1 Sequencer filtered alarms ................................................................................................ 23
9.1.2 Automation system alarm................................................................................................ 23
9.1.3 Direct Alarms .................................................................................................................... 24
9.1.4 Programming alarms in the PLC. ..................................................................................... 24
9.2 Manual Permissives ......................................................................................................... 24
10 L1-L2 Interfaces ............................................................................................... 24
11 DOCUMENTATION .......................................................................................... 25
11.1 Standard Nomenclature for the symbol names (Auxiliary Text) .................... 25
11.1.1 Sequence related tags ..................................................................................................... 25
11.1.2 Input/output tags ............................................................................................................ 25
11.2 Graphics Representation of the Sequencers ..................................................... 27
12 ANNEX 1 .......................................................................................................... 29
12.1 Variable list in accord to IEC63416 norm........................................................... 29
13 ANNEX 2 .......................................................................................................... 31
13.1 Code list, Devices/Equipment............................................................................. 31
3/31
1 DOCUMENT OBJECTIVE
This document describes the standards for the organization and preparing the
software for CONTROL LOGIX™ PLC in the TENARIS facilities.
2 PLC PROGRAMMING STANDARDS
2.1 General Principles

The software to run all mechanical equipment (drive) must be built in
accordance with the sequential programming principle in case of sequential
processes. Sequential programming is based on the use of state logic
machines.
Each sequencer is therefore built into a series of states and transitions that
define the change from one state to another.
All the software shall be programmed in LADDER LOGIC or Block Diagram

according with facility’s standard with exception of these functions that
contains complex calculations that can be programmed with STATEMENT
LIST. The sequencer must be programmed SFC.
The only signals that could interrupt the normal execution of the sequence
are the change to manual mode, the Emergency, the fault and the Blocked.
In all cases there is an effort to respect the program’s organization.
The objective is to try to reduce the length of time in maintenance

interventions providing quicker diagnostics while always safeguarding
personnel and devices or equipment.
It is important to correctly identify the distinct sequencers in the project

phase.
The criteria used to select a sequencer should be one of the following:
- Each individual mechanism must have its own sequencer.
- Some cases it is necessary to use an especial sequencer for tracking

purposes.
- The interfaces with L2 could require the use of sequencers instead of

directly field sensors.
2.2 Safety
The structure of the sequencer states ensures that the signals emitted from
sensors in the field are detected by the program only when the automatic or
semiautomatic execution is in the corresponding step.
This ensures that the accidental triggering of a sensor does not cause any
drive to move in general.
4/31
Only the “piece presence” signal (See chap. 5.1.2) can initiate a sequence in
automatic mode.
3 PLANT STRUCTURE AND OPERATING MODES
3.1 Area and zone

An AREA is defined in terms of an emergency concept, in other words an
Area of the plant defines an emergency area.
When an emergency is tripped, all the sequencers must go to the Emergency

Step.
In this state, no new output will be enabled and the rest of the outputs will
have their voltage supply cut off.
Each AREA is subdivided into one or more ZONES, in accordance with

operating needs for the different modes of operation (manual, automatic,
semiautomatic, block). Each zone must have ONLY one operation mode and
the “On Cycle” signal for the zone (the lamp that when is on means that the
zone is in automatic) must be build according the state of the sequencers
inside the zone.
5/31
One zone can have one or more drives, and consequently it can have one or
more connected sequencers.
3.2 Operating Modes

There are three defined operation modes: manual, semiautomatic and
automatic. In machines where the operator needs to change the tools shall
appear a fourth mode called “BLOCKED”. This mode should be used when
applicable.
Therefore there is a 3-mode operational selector situated in each main pulpit

zone which controls the operation and movement of equipment in that zone.
With this concept of defining each zone as an “Island”, it is possible to

operate a zone in manual while the rest of zones continue to operate in
automatic mode.
The automatic mode typically includes the possibility of having an automatic

stop where the machine will stop before the next sequence step starts. This
operation can be done switching to semiautomatic mode on the fly or using
the End of Cycle command.
3.2.1 Automatic
In automatic mode the plant works without the intervention
of the operator, who in fact only oversees the operation.
Some cases the process needs the intervention of the
operator in automatic mode to take any decision. Therefore,
suitable signals must be installed for the process variables to
be watched.
Each zone must have an associated start condition diagnosis
where it is possible to identify the missing conditions to enter
in cycle. When all the conditions are available the lamp in
"start cycle" button must blink. After the operator press this
button, if all the sequencers enter in Automatic cycle the lamp
remains on. If for any reason the machine exit from the
automatic cycle (one sequencer goes in emergency for
instance) the cycle must stop (suddenly or once the current
piece been processed depending of the process), the light
must be off and in the Alarm system should appear the origin
of the stop
The transition from automatic mode to semiautomatic does not

interrupt the running cycle. The cycle will stop once it is completed
(stop at the end of the cycle).
The transition from automatic mode to manual mode interrupts the

cycle that is being executed.
The overall objective is to keep the machine running in

automatic mode as much as possible.
6/31
Another way to stop the automatic sequence is using an End of Cycle

button to stop at the end of a cycle without changing mode. This can
be used to change the supervision presets to conduct a routine
inspection, etc.
The sequencers inside the zone must be in the state according with
the zone mode. The transition from Automatic to Manual mode, for
instance, makes all the sequencers go to the manual step.
3.2.2 Semiautomatic
The semiautomatic operating mode is an aid to the operator to handle

situations in which it is not possible to work in automatic mode. Semi
automatic mode is optional.
This is to be used for one of the following cases:
• To perform one complete cycle and then stop. The operator will
turn the machine to semiautomatic mode and then press the start
cycle button. While the zone remains in this mode, the sequence
doesn’t start until the start cycle button is pressed again.
• Simulate a complete cycle when there is no piece present. The

operator will turn the machine to semiautomatic mode and press
the applicable command button, simulating a piece presence.
Thus, if the cycle ends properly the operator is sure that there are no
electrical or mechanical problems.
• End a complete cycle of one or more sequencers in cascade both

with and without a tube on line.
In this case, the operator, always in semiautomatic, has a run button

with a step by step function. At the end of a cycle phase, the button
light will begin to flash to request authorization for the next phase.
3.2.3 Manual
In this operating mode, the operator may directly move the

equipment.
The operator has to be restricted by software or hardwired

from making any movement or adjustment that could injure
personnel or damage the machinery.
When in this mode, devices can be operated either from the main
control cabin (main pulpit in the control room used by operations
personnel) or from the local control cabin (local pulpit in the field
generally by maintenance personnel).
3.2.4 Blocked
This operative mode is used in cases where the operator has to access
the machines for operative procedures (ex. Changeover, tool change,
etc). It has to be a 2-mode operation selector hardwired directly to
the block circuit (not through the PLC) to de-energize the necessary
7/31
equipment; on the other hand, all the sequencers located in the same
zone of the device blocked must go to the “Block” state shown in
Figure 2.
The best practice is to completely end the machine cycle

switching to semiautomatic mode (or End of Cycle push
button) and after all devices stop switch to Block mode.
This selector must have the possibility to lock out.
3.3 Local-Remote command enable

Local-remote command enable is used when one device can be
controlled from more than one place.
This control will be managed by a lighted push button. The HMI will also
have an indicator with the name of the Operator Panel that has the
control.
The programming of the light is the following:
Light Off: Control is in another Operator Panel.
Light Flashing: Control is released and can be taken by any Operator

Panel.
Light On: Control Enabled in this panel.
4 PULPIT: GENERAL CONDITIONS
4.1 Traditional pulpits

The traditional operating pulpits shall be organized in logical modes in
accordance with the definition of the area and the mill zone, trying to always
follow the process flow.
The following controls shall be installed in each area:
• Emergency red mushroom button: This electrically stops the

devices in the area. Could be used luminous mushroom button as
optional.
• Control Power On white luminous button: The white signal shows

the area is ready.
• Blocked selector (if need it)
The following modes could be installed in each zone:
• Mode three position selector: Automatic, semiautomatic and

manual.
• Cycle Start green illuminated button:
8/31
• When all interlock conditions and “first piece condition” are

ready this button starts flashing; when pressed, auto mode
is engaged and if all the sequences start the button
remains steady. If some condition trips out at least one of
the sequencers in the zone, the auto goes off and the
button light turns off.
• End of Cycle button (if necessary).
• Reset red illuminated button:
• When at least one sequence is in Fault (step 29) this button

starts flashing. To reset the fault it is necessary to press
this button. If the zone is in automatic mode, it is
necessary to press the Start Cycle push button to start the
movement of this sequence after the reset command.
The following shows us an example of how the button layout may be in a

traditional pulpit:
Figure 1 - Traditional pulpit example.

The selectors, buttons and signal lights used for manual commands shall be
on the side or on the lower part of the pulpit.
NOTE: Mode Selectors and the Start Cycle push buttons can be either
hardwired (default option) or programmed into HMI application (alternative
option).
4.2 Programmable panels (Panel View)

This type of panel is selected when there is a high quantity of devices to be
operated. Thus, the panels become smaller and more flexible.
The “emergency” red mushroom pushbutton, the white luminous “power on”
pushbutton and the “Block” selector always remain hardwired for safety
reasons, as described in the previous point for traditional pulpits.
The following selectors could be maintained in the traditional type or in the

HMI:
9/31
The Mode selector of each zone
The “Cycle Start” green push button
The “End of Cycle” selector
Panel Views, when possible, should not be used to set machine preset values;
it is advisable to perform this action from the respective level 2 automation
systems.
5 LOGICAL STRUCTURE OF A SEQUENCER

The logical structure of the sequencer should be according Figure 2.
Steps 1, 2, 4, Cycle End, Manual, Block, Fault and Emergency are
common for all sequencers; from Step 4 to Cycle End the number of
steps used will depend on the complexity of the sequence. Each step
evaluates a logical condition (transition) before jumping to the next one.
From step 4 is advisable to leave an open number for each 2 steps so as to

make easier future programs modification. Any step from step 4 on can be
used as a “GO TO” instruction and this will depend on the process of each
sequencer.
10/31
Figure 2 - Logical Structure in sequencer (simplified)

For all those devices conceived to operate with manual intervention of the
operators, despite the position of the Mode Selector switch, the structure
shown in Figure 2 must be also taken into account. In this case, only Steps
1, Manual, Block, Fault and Emergency will be present. E.g.: one pin stop
that must release pipes to feed the line.
5.1 Transitions
5.1.1 Initial conditions (automatic and semiautomatic cycle)

Transition to step 2
In this transition the “initial conditions” are verified; the “initial

conditions” are all those conditions necessary to start an automatic or
semiautomatic cycle. Usually, permanent conditions are as example;
motor protections and drives ready, hydraulic services ready, etc.
Also the Automatic or semiautomatic mode selection and the cycle

start button from the operator are evaluated together with the “initial
11/31
conditions”. Mode selection by itself shall not initiate machine

operation. The reason for a validation of the automatic start is detailed
in the norm EN 60204.
5.1.2 Start Cycle Movement conditions

Transition from step 2 to step 4
This condition enables the execution of the sequence and is clearly

grouped in:
Piece Presence condition:
This signal verifies that a new piece is present to start a cycle; it can
be a sensor that detects the physical presence of the piece, or also a
signal coming from another previous sequencer that gives the
permission to start the cycle (synchronization).
Furthermore, the “end of cycle” selector or pushbutton is evaluated in

this step; it must block or stop the continuity of the automatic cycle
by the operator. The sequencer will remain in step 2 “Idle” until
operator removes the end of cycle signal and the operator press the
Start Cycle push button.
Enable Conditions:
These are enabling conditions that come from the machines

downstream (adjacent machines) and other external devices or
systems such as Level 2, enable conditions are as example; ready to
receive from next machine or sequencer, tracking enable from Level
2. The main purpose of these conditions is to verify that the operation
of delivery or receiving of the piece can be correctly managed.
Starting Conditions:
These are the necessary conditions of the machine to start the

movement (for example: “home position”) that may no longer be
present. These conditions are related to the machine (sequence) itself.
5.1.3 Actions
Transition from step 4 to step 26-42-58
During the running steps of the sequencer (4 to 26-42-58) the

transitions must be designed and implemented according to the
application needs of the machine. It is strongly recommended to use
pair steps, leaving as Spare the odd steps. It means 4, 6, 8, and so
on.
5.1.4 Block
Transition to step 31-47-63
The transition to this step is basically controlled by the Block Mode

selector.
12/31
5.1.5 Cycle_End
Is the transition to the last step in automatic or semiautomatic mode.
5.1.6 Fault
The conditions that lead the sequencer into step 29-45-61 are critical
failures of the device. Some examples are:
-Running Steps Time out.
-Lost of some Permanent Conditions, such as drive tripped and all

safety interlocks according to EN 60204.
The last sequence step before going to the Fault one should be
memorized in order to have more information for later diagnosis.
To get out from the step 29-45-61 the Reset PB has to be pushed
when the fault conditions are not longer present. From the Step 29
the sequencer will go to Init State (Step 1).
5.1.7 Change from automatic or semiautomatic to manual mode

The transition to this step is basically controlled by the Manual Mode

selector. To go out form this step it is required to select Automatic or
Semi Automatic Mode.
5.1.8 Hold
During the running steps of the sequencer (4 to 26-42-58) the

transitions to/from to the hold step can be designed and implemented
according to the application needs.
Any step of the sequence where it is required to wait other sequencer

or an operator action will be part of the main movement sequence.
5.1.9 Emergency stop

The state machine changes to step 32-48-64, every time the

Emergency Stop Mushroom PB is pressed by the operator, and/or the
protections implemented in the system drive to emergency stop,
regardless of the current step of the sequencer.
Once the emergency conditions are not present anymore (electrical

chain has been re-established), to get out from the Emergency Step
13/31
the Control Power ON PB has to be pushed by the operator. From the

Emergency Step the sequencer will go to Init State (Step 1).
5.2 Steps of the sequencer

Please refer to Figure 2.
The steps of the sequencer are numbered with a consecutive number starting
from 1 to 32-48-64.
In order to manage medium complex sequencers, a numbering system of 1

to 48 may be adopted and to handle more complex sequencers a numbering
system from 1 to 64 can be adopted.
Some numbers are reserved for the same steps for all the sequencers: this
allows for a fast and effective development of the diagnostic activity.
5.2.1 Step 1 – Waiting AUTOMATIC Start
This is the initial step of every sequencer according with EN 61131.

The sequencer goes in this step every time that:
- The PLC is turned on or restarted (First Scan);
- The operating mode switches to/from manual mode;
- The Block selector switches.
- After a reset command by the related pushbutton, coming from an

emergency or failure condition.
In this step the “initial conditions” are checked (See chap. 5.1.2).
If the conditions are verified, after pressing the start cycle button
sequencer goes to Step 2 and the light on the pushbutton remains on.
5.2.2 Step 2 – In AUTOMATIC Cycle
In this step the sequencer is waiting to start the automatic cycle

movements. This is the natural standby step for the sequencers where
it is waiting for the conditions to start running.
5.2.3 Step 3
Not used.
5.2.4 Step 4 to 26-42-58 – In Cycle
STATE 4. - It is the first step of the mechanical movements of

the machine. Starting from this to the step 26-42-58 the
sequence follows the cycle of the specific machine controlled;
each step has an action during the normal sequence.
5.2.5 Step 31-47-63 – Block Mode

14/31
This step is activated when the block mode is selected.
Independently of the status of the sequencer, at the moment of

changing in block mode the sequencer will strictly change to the step
31-47-63. The exception are the step 32-48-64 (emergency) and the
step 29-45-61 (Fail Stop) that for safety reasons have the highest
priority.
5.2.6 Step 28-44-60 – Cycle End
It is the last step that can be used for the automatic cycle of the
sequence. After the last step is completed the sequencer returns to
the step 2 (despite the zone is in auto or semi mode).
5.2.7 Step 29-45-61 - Fault
This step is used when a malfunction or fail condition appears and the
sequence must be stopped immediately, implementing a stop function
category 2, a controlled stop with power left available to the machine
actuators according to EN 60204.
5.2.8 Step 30-46-62 – Manual mode
This state is activated when the manual mode is selected.
Independently of the status of the sequencer, at the moment of

changing in manual mode the sequencer will strictly change to the
step 30-46-62. The exception are the step 32-48-64 (emergency), the
step 29-45-61 (Fail Stop) and the step 27-43-59 (block) that for
safety reasons have the highest priority.
5.2.9 Step 27-43-59 – Hold.
This state is used as a non action state; its purpose is to be used

when a special situation requires a HOLD of the sequence, without the
timeout control. The necessity of these conditions has to be defined
for each application, considering the specific requirements.
5.2.10 Step 32-48-64 - Emergency
When an emergency condition occurs, the sequencer must go to step

32-48-64. The emergency conditions must be managed according the
electrical safety normative. This step has the purpose to manage the
automation conditions during the Emergency Stop Category 0 an
uncontrolled stop by immediate removal of power to the machine
actuators or Emergency Stop Category 1 a controlled stop with power
available to the machine actuators to achieve the stop and then
removal of power when the stop is achieved all this according EN
60204.
Once the sequencer has reach this state of Emergency Stop, the state
of all variables and outputs must be driven to their safety state.
5.3 Sub-sequencers
15/31
A sub-sequencer is a subset of steps that does not verify all the control
conditions like a normal sequencer does.
Sub-sequencers can be used in the following cases:
§ In complex machines, when in one step of the main sequence is

necessary to carry out a series of operations;
§ When it is necessary to check a series of conditions to trigger one

event.
Figure 3 - Sequential function charts (SFC) with sub-sequencer
16/31
6 PROGRAM DISTRIBUTION
The PLC programming requires that an order of programming routines be
safeguarded so that the following criteria are always represented:
• Controller “PLC Name”
• Controller Fault Handler
• Fault Handler
• Fault Handler Routine
• Power Up Handler
• Power Up Handler
• Power Up Handler Routine
• Task
• Main task
• P01_Inputs
• R00_Main
• R01_Inputs
• P02_Main _ Program
• R00_Main
• R01_Filtering
• R02_Level 2
• R03_HMI
• R04_Scaling
• R05_Initialization
• R06_Diagnosis
• R07_Alarms
• R08_Operative_Modes
• R09_Outputs
• P03_Services
• R00_Main
• R01_Alarms
• R02_HMI
• R03_Auxiliaries
• R06_Outputs
• S01_ROLLING_STOP_A1RSP01
• R00_Main
• R01_Alarms
• R02_HMI
• R03_Auxiliaries
• R04_Transitions
• R05_Sequencer
• R06_Outputs
• R07_Handshake
• S02_ROLL_CONVEYOR_A1RCO01
• R00_Main
• R01_Alarms
• R02_HMI
• R03_Auxiliaries
• R04_Transitions
• R05_Sequencer
• R06_Outputs
• R07_Handshake
17/31
• Sxx_DeviceName_ElectricTag
• R00_Main
• R01_Alarms
• R02_HMI
• R03_Auxiliaries
• R04_Transitions
• R05_Sequencer
• R06_Outputs
• R07_Handshake
• P99_Outputs
• R00_Main
• R01_Outputs
6.1 Fault Routine

This routine should be created in the following path: Controller “PLC
name”\Controller Fault Handler\Fault Handler Routine and it is destined
to read the PLC fault code (the condition may be a program fault or
another condition). Faults are categorized by severity into major faults
and minor faults and can be trapped by the controller fault handler
program to take corrective action.
6.2 Power Up Routine

This routine should be created in the following path: Controller “PLC
name”\Power Up Handler\Power Up Handler Routine and it is destined to
execute logic only once during start-up.
6.3 Main Task

The Main Task is cyclic and contains all the programs that control the line
or devices. We can find below the description of the different kind of
programs that are included into this main task.
6.3.1 Inputs Program

The periphery image is copied into this program, so the inputs are kept in
the same value at least during one scan of the PLC.
6.3.2 Main Program

Contains the general logic needed and used in the rest of the programs.
For example: signal scaling, inputs filtering and so on. An exhaustive list
is described in the following points.
6.3.2.1 Main Routine

The Main Routine controls the order in which the rest of the routines are
executed.
6.3.2.2 Filtering
Into this routine are filtered the digital inputs that need this kind of
treatment, for process reasons.
18/31
6.3.2.3 Level 2
In this routine we perform data validation with level 2 system
(e.g.:presets).
6.3.2.4 HMI
General logic for Level 1.5 operations such as HMI shall be programmed
in this routine.
6.3.2.5 Scaling
Analog inputs and outputs are filtered and scaled into this routine, to
convert them from raw to engineering values or vice versa.
6.3.2.6 Initialization
This routine initializes all the constants and variables that require to be
initialized.
6.3.2.7 Diagnosis
Everything related to generating a diagnosis to provide the necessary
process alarms is programmed in this file.
6.3.2.8 Alarms
All the general alarms and the ones generated in a diagnostic routine
shall be programmed here to be read for any superior level.
6.3.2.9 Operative Modes

The selection of the operative modes (auto, semi, manual, etc.) for the
different zones of the line is programmed into this routine.
6.3.2.10 Outputs
Logic for general purpose outputs is programmed in this routine.
6.3.3 Services
The logic for auxiliary services (for example: one hydraulic power unit)
should be programmed into this program. According to the requirement
of the plant it could exist more than one services program.
6.3.4 Sequencers
The software that controls the different devices of the line is programmed
in these program folders. The typical structure is described in the next
points.
6.3.5 Outputs Program

The periphery image is copied into this program, so the physical outputs
are updated at the end of the PLC scan.
19/31
7 SEQUENTIAL FUNCTION CHARTS (SFC) OF THE

PROGRAM
The sequential function charts (SFC) of the sequencer is shown in figure 4.
Figure 4 - Sequential Function Charts (SFC)
7.1 Standard for the implementation of the sequencer

Sequencers are managed as programs called “Sxx_DeviceName_ElectricTag”,
where “xx” is the number of the sequencer.
Sequencer Nº 1, for example, is the program:

S01_"DeviceName"_”ElectricTag.
Sequencer Nº 2 is the program: S02_"DeviceName"_”ElectricTag and so on

up to S32 that is the maximum number for programs to be scheduled in the
continue task).
In each sequencer program, we should find everything related to the process

under control. For example:
Where:
Program Tags: Include all local variables declaration
R00_Main: The Main Routine controls the order in which the rest of the
routines are executed.
20/31
R01_Alarms: Contains all necessary logic for diagnosis and alarms of one
particular device.
R02_HMI: Contains all necessary logic for HMI related with the devices
controlled in this sequence.
R03_Auxiliares: Contains all combinational auxiliary logic used by the

sequencer (For example: manual permissives, Sequencer DRUM or actual
state conversion)
R04_Transitions: Contains all combinational logic for the sequencer

transitions.
R05_Sequence: The structure of the sequence in SFC language is

programmed into this routine.
R06_Outputs: Includes all field outputs management.
R07_Handshakes: Logic for Level 2 handshakes related to one particular

device (if exists) is programmed into this routine. This includes pipe tracking,
production handshakes, etc.
8 DIAGNOSIS ORGANIZATION
The organization of the diagnosis routine is shown in figure 5.
Figure 5 - Organization of the diagnostic file
8.1 Standard for the diagnosis implementation

The general diagnoses are performed in the routine:P02_Main_Task\
R06_Diagnosis; the diagnosis of a specific sequencer is performed in routines
“Sxx_DeviceName_ElectricTag\R01_Alarms” for each sequencer program.
In the routine P02_Main_Program\R06_Diagnosis, we find:
•The automation system logic alarm rungs
•The direct alarm logic rungs
Sequencer diagnosis.- Sequential diagnosis forms part of a Subroutine

(Sxx_DeviceName_ElectricTag\R01_Alarms) where all alarm and warning
conditions related to a given sequencer should be programmed.
Inside the routine Sxx_DeviceName_ElectricTag\R01_Alarms we should find:
· Rungs for logic alarm.
· Rungs for logic warnings.
21/31
8.2 Standard diagnosis information

Diagnosis information related to typical devices shown below shall be
included into the program to be collected by Level 2, with the exception of
those devices that are unable to be diagnosed:
• Discrete I/O
• Analog Sensors
• Motors
• Drives
• Cylinders
• Level 2
9 DIAGNOSIS PROGRAMMING
The “Sxx_DeviceName_ElectricTag\R01_Alarms” routine of every sequencer
and the “P02_Main_Program\R07_Alarms” routine contain all the necessary
alarms that will be collected by Level 2.
9.1 Alarms
In the “Sxx_DeviceName_ElectricTag\R01_Alarms” routine, the rungs relative
to the diagnostic system are programmed.
The alarm bits are sent from the PLC to the Level 2 system via Ethernet
network.
In the HMI is recommended to program an indicator that shows when there is

at least one alarm activated.
The alarm display system must:
• Show only real alarms.
That means that we should filter the alarms taking into

account the priority of them, to display only the alarms
that are really present. For example, if the emergency
stop is pressed, we should not see in the Level 2
application one alarm generated by an electrical device
that has lost its normal conditions due to this situation.
• Be as clear as possible with the description of the failures.
Generic type of descriptions such as “lack of transition

from … to … “ or “lack of initial condition “ are not
acceptable without further explanations.
Descriptions of accumulated indications of a failure: such

as “lack electrical ready” are not acceptable because the
operator does not know immediately whether or not the
22/31
cause is for example if is out a thermal protection or a

breaker switch is out or a failure in the converter.
The alarms are mainly divided into two groups:
• Filtered sequencer alarms that to be activated require

when the sequencer is in a pre-determined step.
• Direct alarms that are activated in any step that the

sequencer is in.
9.1.1 Sequencer filtered alarms
The filtered alarms are displayed in one or more sequencer steps.

Using the sequencer description as a reference, we can subdivide into:
• Sequence Alarms: when the sequencer remains in the

Step 4 or one of the successive steps more than an
expected amount of time.
• Emergency
9.1.1.1 Sequence alarms
The sequence alarms are timers associated with steps from 4 to

26-42-58.
These alarms are triggered due to a delay or lack of sensor

signal needed to transition the sequencer from the actual step to
the next one.
Steps from 4 to 26-42-58 do not have, unlike the first 6 steps, a

precise function and meaning.
It is therefore good to try to use all the steps necessary so that

the transition is conditioned on one single event.
This means building sequencers with a high number of steps,

with the advantage that each lack of transition automatically
triggers an individual alarm.
It is important to check things out whenever a sequence alarm is

triggered.
9.1.1.2 Emergency
When the operator presses the emergency button the sequence

must go to step 32-48-64 and the corresponding alarm should
be generated to be read by Level 2.
9.1.2 Automation system alarm
This alarms diagnosis the anomalies of the automation system.
These alarms indicate:
23/31
• Low batteries
• Overall rack failure
• Failure of some major flaw present like the “watch dog”
• Failure of individual racks.
• Etc.
9.1.3 Direct Alarms
These alarms indicate a problem with the line under control and
require direct action in the mill.
The motives for direct alarms could be:
• Burnt out fuses.
• Thermal tripping
• No voltage.
• Hazardous service
9.1.4 Programming alarms in the PLC.
Alarms remain activated until the cause that generates them disappears;
they are not retained in Level 1.
The description of each alarm bit should be “Device Name+Electrical

Tag+Comments”. The number of the alarm should be unique. For example,
the description of a drive alarm related to a dual arm lifter should be: “Dual
Arm Lifter A1DAL01- Drive Fault”.
9.2 Manual Permissives

Manual permissives will be shown in the HMI to help the operator. This
permissive show if the conditions to move the device in manual mode are
met. There shall be an indicator in the HMI where it is show in green if the
conditions are done or in red if it is not.
10 L1-L2 Interfaces
The communication between the PLC and Level 2 systems will be carried out
using standard AOI (Add On Instructions), the use of these instructions
ensure that the data exchange between L1 and L2 is the same regardless of
who develops the interfaces.
Examples of standard AOI to be used are: Alarms, Presets, Events, Product

curves, Cycle Time, Sequencers, Initial Conditions, etc.
For more information refer to document “AOI_HANDSHAKES_EN_Rel.X.doc”
24/31
11 DOCUMENTATION
All the documentation to be submitted by the supplier will be in Spanish or
English depending on what the official language of the mill is and the
documentation that must be submitted with the PLC software project is as
follows:
• Flowchart for each sequencer prepared with UML (alternatively Visio 2007
or Word 2007) and supplied in hardcopy and electronic documentation.
• Panel View developments will be include a user manual with detail

explanation of all screens, if the system use any kind of programming as
Visual Basic, C++ etc it will be completely explained and documented in
the manual. Manual should be supplied in electronic and hardcopy
versions. Include all the project files and in the case of Panel View Plus
include the “*.APA” file in the electronic documentation CD.
• Input/Output list prepared with Microsoft Excel.
• Submit functional specification for maintenance as per form supplied in

hardcopy and electronic documentation.
• Level 1 – Level 2 tags list prepared with Microsoft Excel.
11.1 Standard Nomenclature for the symbol names (Auxiliary Text)

The nomenclature that must be used to respect the symbolic names used in
the interior of the sequencers and in the diagnosis is described later.
11.1.1 Sequence related tags
The tag for the program should be called as:
“Sxx_Devicename_ElectricTag”
For example: S01_Roll Conveyor_A1RCO01 for one roll conveyor sequence

tags.
To reference to a specific step will be used:
ElectricTag_Seq.STEP[n].x
Where “n” is the number of the step and “x” is the SFC standard to indicate
that the variable is a step of the sequencer
If ElectricTag_Seq.STEP[n].x is ON the step is active otherwise if it is OFF

the step is not active.
11.1.2 Input/output tags
The I/O tags should be called like it is in the Input/output diagram and the
description should be related with the instrumentation tag and description.
Example:
25/31
This I/O tag will be the alias of the real input/output module tag.
The routine Main Task\P02_Main Program->R01_Filtering is used to filter the

Inputs. As result it is obtained the tags used in the rest of the logic. The
name of the follow the rule: “IECCode_DeviceName_Description”. Eg:
26/31
BX_A1SAL05_Piece_Presence_East to reference to an inductive sensor used

to detect the piece presence of the single arm lifter.
11.2 Graphics Representation of the Sequencers

The graphic representation of sequence is a Grafcet type, detailing the
number of the sequencer, description of the function it performs, the way the
field elements act (NA or NO) indication of command that is made.
We can see the standardization of the symbols to use in the flowcharts.

Attached to each flowchart is a template with each of the first piece and start
up conditions.
1. - Normally open contact:
2. - Normally closed Contact:
3. - Positive transitional contact:
4. - Negative transitional Contact:
5. - AND of 2 contacts:
27/31
6. - OR of 2 contacts:
7. - Sequence pass:
8. - Temporized:
28/31
12 ANNEX 1
12.1 Variable list in accord to IEC63416 norm

GENERAL
Code Description
A1 MV Cell
A2 PWC
A3 MCC Board
A4 Speed Drives Board
A5 Auxiliary Board
A6 PLC Board
A7 Control Desk
A8 TDA Board
A9 PC Racks
CP Junction Box
CB Terminal Block Board
AM I/O Module
ATN Pneumatic Stand
ABH Hydraulic Stand
AT Electronic Board, Amplifier
Command Elements
Code Description
SH Lighted Pushbutton
SPE Emergency Stop Pushbutton
SJ Joystick
SM Manipulator, Pedal Switch
SP Pushbutton
SS Selector Switch
PD Display
PH Light Indicator
PA Acoustic Indicator
Digital Control Elements
Code Description
BD Hot Metal Detector
BS Limit Switch
BK Photocell
BF Flow Switch
BL Level Switch
BP Pressure Switch
BT Temperature Switch
BV Null Speed Switch
BX Proximity Switch
Analog Transducers
29/31
Code Description
FT Flow Transmitter
MT Humidity Transducer
PT Pressure Transmitter
WT Load Cell
PDT Differential Pressure Transmitter
GP Pulse Generator (Encoder, Resolver)
GD Length Measurement (ultrasonic, laser)
TT Temperature Transducer
TE Thermo-element (PT100, Thermocouple)
ELECTROVALVES
Code Description
YH Hydraulic Valve
YM Control Valve
YN Pneumatic Valve
YP Proportional Valve
YS Servo Valve
YV Safety Valve
Electrical Protection and Devices
Code Description
QS Circuit Breaker
QB Switch, Motor Proteccion
QF Thermomagnetic Proteccion
OL Fuse
K.. Contactor, Relay
KT Timer
TF Frequency Converter
TS Soft Starter
TP Power Transformer
TC Control Transformer
30/31
13 ANNEX 2
13.1 Code list, Devices/Equipment
Tenaris DEEN -
Device and Equipment List_Rev3.0.xls
31/31

AUDE STD 01 - Rockwell - PLC Programming Standard - Rel 2.0

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

AUDE STD 01 - Rockwell - PLC Programming Standard - Rel 2.0

Transféré par

Droits d'auteur :

Formats disponibles

Internal Distribution:

Tenaris DEEN, AUDE

1 DOCUMENT OBJECTIVE .................................................................................... 4

2 PLC PROGRAMMING STANDARDS ................................................................... 4

3 PLANT STRUCTURE AND OPERATING MODES................................................. 5

4 PULPIT: GENERAL CONDITIONS........................................................................ 8

5 LOGICAL STRUCTURE OF A SEQUENCER ....................................................... 10

6.3 Main Task ......................................................................................................................... 18

7 SEQUENTIAL FUNCTION CHARTS (SFC) OF THE PROGRAM .......................... 20

9 DIAGNOSIS PROGRAMMING .......................................................................... 22

10 L1-L2 Interfaces ............................................................................................... 24

2 PLC PROGRAMMING STANDARDS

2.1 General Principles

All the software shall be programmed in LADDER LOGIC or Block Diagram

In all cases there is an effort to respect the program’s organization.

The objective is to try to reduce the length of time in maintenance

It is important to correctly identify the distinct sequencers in the project

The criteria used to select a sequencer should be one of the following:

- Each individual mechanism must have its own sequencer.

- Some cases it is necessary to use an especial sequencer for tracking

- The interfaces with L2 could require the use of sequencers instead of

3 PLANT STRUCTURE AND OPERATING MODES

3.1 Area and zone

When an emergency is tripped, all the sequencers must go to the Emergency

Each AREA is subdivided into one or more ZONES, in accordance with

3.2 Operating Modes

Therefore there is a 3-mode operational selector situated in each main pulpit

With this concept of defining each zone as an “Island”, it is possible to

The automatic mode typically includes the possibility of having an automatic

The transition from automatic mode to semiautomatic does not

The transition from automatic mode to manual mode interrupts the

The overall objective is to keep the machine running in

Another way to stop the automatic sequence is using an End of Cycle

The semiautomatic operating mode is an aid to the operator to handle

This is to be used for one of the following cases:

• Simulate a complete cycle when there is no piece present. The

• End a complete cycle of one or more sequencers in cascade both

In this case, the operator, always in semiautomatic, has a run button

In this operating mode, the operator may directly move the

The operator has to be restricted by software or hardwired

The best practice is to completely end the machine cycle

This selector must have the possibility to lock out.

3.3 Local-Remote command enable

The programming of the light is the following:

Light Off: Control is in another Operator Panel.

Light Flashing: Control is released and can be taken by any Operator

Light On: Control Enabled in this panel.

4 PULPIT: GENERAL CONDITIONS

4.1 Traditional pulpits

The following controls shall be installed in each area:

• Emergency red mushroom button: This electrically stops the

• Control Power On white luminous button: The white signal shows

• Blocked selector (if need it)

The following modes could be installed in each zone:

• Mode three position selector: Automatic, semiautomatic and

• Cycle Start green illuminated button:

• When all interlock conditions and “first piece condition” are

• End of Cycle button (if necessary).

• Reset red illuminated button:

• When at least one sequence is in Fault (step 29) this button

The following shows us an example of how the button layout may be in a

Figure 1 - Traditional pulpit example.

4.2 Programmable panels (Panel View)