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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
6 PROGRAM DISTRIBUTION............................................................................... 17
6.1 Fault Routine.................................................................................................................... 18
6.2 Power Up Routine ........................................................................................................... 18
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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
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1 DOCUMENT OBJECTIVE
This document describes the standards for the organization and preparing the
software for CONTROL LOGIX™ PLC in the TENARIS facilities.
Each sequencer is therefore built into a series of states and transitions that
define the change from one state to another.
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.
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.
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Only the “piece presence” signal (See chap. 5.1.2) can initiate a sequence in
automatic mode.
In this state, no new output will be enabled and the rest of the outputs will
have their voltage supply cut off.
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One zone can have one or more drives, and consequently it can have one or
more connected sequencers.
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
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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
• 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.
Thus, if the cycle ends properly the operator is sure that there are no
electrical or mechanical problems.
3.2.3 Manual
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
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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.
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.
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NOTE: Mode Selectors and the Start Cycle push buttons can be either
hardwired (default option) or programmed into HMI application (alternative
option).
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.
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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.
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5.1 Transitions
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).
Enable Conditions:
Starting Conditions:
5.1.3 Actions
Transition from step 4 to step 26-42-58
5.1.4 Block
Transition to step 31-47-63
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5.1.5 Cycle_End
Transition to step 28-44-60
5.1.6 Fault
Transition to step 29-45-61
The conditions that lead the sequencer into step 29-45-61 are critical
failures of the device. Some examples are:
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).
5.1.8 Hold
Transition to step 27-43-59
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The steps of the sequencer are numbered with a consecutive number starting
from 1 to 32-48-64.
Some numbers are reserved for the same steps for all the sequencers: this
allows for a fast and effective development of the diagnostic activity.
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.
5.2.3 Step 3
Not used.
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).
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.
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
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A sub-sequencer is a subset of steps that does not verify all the control
conditions like a normal sequencer does.
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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
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• 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
6.3.2.2 Filtering
Into this routine are filtered the digital inputs that need this kind of
treatment, for process reasons.
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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.
6.3.2.10 Outputs
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.
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Where:
R00_Main: The Main Routine controls the order in which the rest of the
routines are executed.
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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.
8 DIAGNOSIS ORGANIZATION
The organization of the diagnosis routine is shown in figure 5.
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• 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.
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• Emergency
9.1.1.2 Emergency
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• Low batteries
• Etc.
These alarms indicate a problem with the line under control and
require direct action in the mill.
• Thermal tripping
• No voltage.
• Hazardous service
Alarms remain activated until the cause that generates them disappears;
they are not retained in Level 1.
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.
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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.
“Sxx_Devicename_ElectricTag”
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
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:
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This I/O tag will be the alias of the real input/output module tag.
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5. - AND of 2 contacts:
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6. - OR of 2 contacts:
7. - Sequence pass:
8. - Temporized:
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12 ANNEX 1
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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
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13 ANNEX 2
Tenaris DEEN -
Device and Equipment List_Rev3.0.xls
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