SERVICES / CONTROL SYSTEM DISCOVERY
Before anyone changes it.
In the sample: four severity A hazards. Releasing the E-stop restores the pump permissive without a reset. See the findings ↓
Site photos and a program backup become as-found drawings, a control narrative, a cause and effect matrix, a live model of the real logic, a ranked findings register and training for every role.
Real process and logic. Engineering by David Landry on an industrial project; model engine, verification and tools by Landry Industrial. Client details changed. Preliminary engineering review draft — not for construction.
E-stop released · low level made · no reset pressed
THE PUBLIC SAMPLE
One real control system.
Site photos in
One program backup. Zero comments.
Latent logic findings, 4 severity A
In 4,012,164 bit checks against the program
Functional test cases pass
Training for every role
WHAT THE SAMPLE FOUND
The sample program holds 14 latent findings: 4 severity A, 6 B and 4 C. Here are the four severity A findings, each with its recommended correction.
APLC-D01
Rungs 2:3, 2:5, 2:11, 2:22
APLC-D02
Rungs 2:5, 2:20–21 · test cases TC-18 to TC-20
APLC-D03
Panel observation O-14 · rungs 3:2, 3:3
APLC-D04
Rungs 2:5, 2:22 · observation O-08
ALSO FOUND · SEVERITY B AND C
WHO IT’S FOR
Owners, managers and engineers need different answers from the same evidence. Choose your role to see what you get.
FOR THE OWNER
For owners and plant managers who have to decide what to fix, what to fund and what to take through MOC.
WHAT YOU GET
The guide below follows your choice. Operators and technicians: find your training videos below.
INTERACTIVE GUIDE
Ten stages on one real system. See what we do, what you receive and why it matters to you. Select a screenshot to enlarge it.
STEP 01 OF 10
Evidence in
Use ← → to move between steps.
STEP 01 / EVIDENCE IN
Site photos, the program backup and any existing documents go into an evidence register. The backup is hashed, so every later statement points to the exact file. The confidentiality boundary is agreed first.
Sample: 11 site photos, one program backup and one line from the plant’s PLC register.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
It starts from evidence you already hold: a camera roll and a program backup.
STEP 02 / AS-FOUND RECORD
Each device is identified from the photos, and the back-panel layout is measured from them to ±0.2 in. Rails, wireways, terminal strips and bundles are classified, terminals recorded and observations logged.
Sample: 4 as-found drawing sheets, a workbook and a panel model.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
A current record of what is really in the panel, including what has been disconnected.
STEP 03 / PROGRAM DECODED
The binary project file is read directly, without vendor software, into a rung listing, address database, I/O map and cross-reference. Wire markers, the program and the door legends are then reconciled signal by signal.
Sample: 3 ladder files, 55 rungs, zero comments or descriptions. Small and fully determined: two trip latches, one timer, seven one-shots.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
An undocumented program becomes something your whole team can read.
STEP 04 / PROCESS & PFD
Signals, equipment and logic come together in a preliminary process flow diagram and a written process understanding: hypotheses, a working basis and the questions to settle on site.
Sample: HCl tank-trailer unloading to receiver V110 with two transfer pumps and dual level transmitters.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
Everyone reviews the same picture of the unit before decisions are made.
STEP 05 / CONTROL NARRATIVE
Sequences, interlocks, alarms and power-up behavior, written from the logic itself. Every statement is cited to the rung that makes it true.
Sample: the as-programmed narrative, including behavior on E-stop and power return.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
Operating knowledge that no longer depends on one person’s memory.
STEP 06 / CAUSE & EFFECT
A cause and effect matrix generated from the logic: each trip, permissive and alarm, its effect on every output, and the rungs responsible. Latched, pulsed and inhibited effects are coded.
Sample: every field-input and internal-state cell exercised in the simulator.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
A sound basis for PHA and LOPA revalidation: what actually happens, not what was intended.
STEP 07 / FINDINGS
A logic weakness review asks what the system does in the situations nobody tests: a broken wire, a held button, power returning. Each finding has a severity, the evidence and a recommended correction; most are tied to a functional test case, the rest to a FAT check or a field hold.
Sample: 14 findings. 4 severity A, 6 B, 4 C.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
A decision-ready list: what to correct now, what to take through MOC and what can wait.
STEP 08 / MODEL PREVIEW
The recorded sample shows the extracted logic running against a model of the plant and hardware. Walkthroughs demonstrate trips, resets and the proposed corrections on the same simulated field. The complete customer model includes a live C&E, narrated scenarios, open-question toggles and verification results.
Sample model: 13 narrated walk-throughs. The verification screenshot records 78/78 test cases and a 40,000-scan equivalence, 0 mismatches.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
Watch a latent hazard play out on screen before it happens in the plant.
STEP 09 / TRAINING BY ROLE
Short narrated videos made on the model, one for each audience: management, operators, technicians, engineers and the people who will use the package. Captioned and ready for your learning system.
Sample: 5 role videos with captions.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
Everyone gets the same story at the depth their role needs.
STEP 10 / PACKAGE HANDOFF
Holds and RFI register, a field-verification checklist, independent cross-check rounds, and package assembly with an index, spelling check and identifier scan. Delivered on your numbering and title blocks, into your document control.
Sample: holds register and field-walk checklist issued with the package.
WHAT YOU RECEIVE
WHY IT MATTERS · OWNERS
A defined deliverable you own, ready for the next decision.
THE MODEL, DEMONSTRATED
Watch the recorded walkthroughs to see how the model exposes trips, resets and open questions. Arrange a guided demonstration to explore the model with us.
HOW WE KNOW IT’S THE REAL LOGIC
This proves our documents match the program. It does not prove what the field devices do — those are the open questions for the field walk.
The customer model includes 13 narrated scenario walk-throughs, a live cause and effect view and “open question” toggles. Interactive models and native files are provided through scoped customer engagements.
TRAINING FOR EVERY ROLE
Short narrated videos made on the sample model, captioned and ready for a learning management system. Choose the one that matches your role. Swipe for all five →
For management · 1:27
What the unloading system does, how little documentation existed, the four severity-A findings (one shown live on the model), and what the package gives you before anyone changes the panel.
For owners, plant managers and engineering managers.
For operators · 1:32
The normal as-found sequence on the CP-101 door buttons and lamps, from hook-up to purge, with the silent horn, the extra reset and the proposed high-high response.
For operators and drivers.
For technicians · 1:27
CP-101 I/O, relays and open fuse carriers, the SSR for LY-X130, the I/O and forces view, an open wire on an energize-to-trip input that gives no trip, and the event log.
For instrument and electrical technicians.
For engineers · 1:36
The extracted ladder executing with live power flow, the live cause and effect, two findings on their rungs, the proposed corrections and the verification shown on the page.
For controls and process safety engineers.
Using the package · 1:30
A guided tour of the offline model (modes, inspector, tabs, walk-throughs, open questions, faults, verification) and where every other deliverable lives.
For anyone who opens the package.
MADE FOR YOUR SYSTEM
In a Full Ground Truth engagement the videos are recorded on the model of your own system, one for each role that needs it. MP4 with WebVTT captions, ready for your learning management system.
See the engagement options ↓WHAT YOU RECEIVE
Explore sample previews below. The complete package, including the interactive model and native files, is delivered as part of your engagement.
The whole story in one document: what the system does, what we found and what to do next.
4 drawing sheets, the as-found workbook and a panel model.
Every rung and address, decoded from the backup.
Signals reconciled against wire markers and door legends, with confidence tags.
Working basis, hypotheses and open questions.
Sequences, interlocks, alarms and power-up behavior, rung-cited.
Every cause and effect, traced to the logic.
Findings ranked A, B and C with recommended corrections.
35 cases with full branch-leg coverage, ready for FAT.
The real logic running offline, with 13 narrated walk-throughs.
Management, operator, technician, engineer and system user.
Numbered open items, each with its owner and closing evidence.
SAMPLE PREVIEWS
Select a preview to inspect it at full size. Sample · client details changed · preliminary engineering review draft — not for construction.
Engineering: David Landry. Model engine, verification harness and document tools: Landry Industrial.
Ground Truth · David Landry · Landry Industrial
Optional follow-ons: a redesign basis (platform selection, panel drawings, bill of materials and a standards compliance review), program conversion and FAT procedures.
SAMPLE DRAWINGS & MODEL PREVIEWS
Select an image to inspect a sample drawing or panel model preview. Swipe for more →
The process as we understood it from the program backup and site photos, with every open question flagged as a numbered hold before anyone walks the site.
ISA-5.1 working-basis PFD built without an owner P&ID: addresses from the extracted program [P], tags from wire markers [M], inferences [I] carry holds H-02 to H-60, with the CP-101 as-found I/O table and legend on the sheet.
A readable slice of the PFD: the truck connection, the receiver, the two pumps and the panel relays that permit them, with open questions marked where they apply.
LT-V110-A/B, LV-V110 and the purge valve tie back to CP-101; K1/K2 (XY-P111A/B) are the pump permissives; octagons are holds and the P / M / I badges give the evidence confidence of each tag.
The front sheet lists what was drawn and, just as important, what still has to be confirmed and by whom.
Index of the X-series as-found sheets, the as-found hold list (H-01 to H-10) with responsibility (owner or integrator), and the reference documents: program backup and printout, the plant PLC register (one line), site photos P01 to P10, the owner's panel standard and the site vendor list.
The door as the operators see it: every light, button and label recorded, including the faded ones.
Front and right-side views at 2"=1' scaled from a photo (door positions +/-0.5 in); door device schedule with the function each device has in the program, tape-printer labels (paraphrased), Type 4X 304SS enclosure identified from its nameplate.
A measured drawing of the inside of the panel produced from one photograph, so the upgrade can be planned before anyone opens the door.
Rectified-photo measurement (5-point homography, +/-0.2 in) at 3"=1': DIN-rail center-line ordinates, device callouts, terminal strips with block counts and open fuse carriers marked, equipment table stating how each part was identified.
Seventeen field observations graded by when they must be acted on, next to what every PLC input and output actually does in the running program.
Observations O-01 to O-17 graded A (act before or during the upgrade), B (fix in the upgrade) or C (note), such as energize-to-trip inputs, open horn fuse carriers and no disconnect; MicroLogix 1200 embedded I/O with wire-marker tag against the function in the as-found ladder.
The as-found back panel drawn to dimension from a photograph: rails, relays, terminal strips and wire bundles where they really are.
Ordinates are DIN-rail center lines on the 21.00 x 21.00 in back panel, measured on a rectified photo to +/-0.2 in; the TS-4 fuse carriers marked X were found open (horn and common alarm outputs).
Every wire on the controller traced to what it does in the program, so nothing is lost when the controller is replaced.
MicroLogix 1200 embedded I/O I:0/0 to O:0/10: wire-marker tag against the function decoded from the as-found ladder (latches, seal-ins, permissives); markers that could not be read are listed as obscured, not guessed.
The same panel as a clickable model: select any part to see what it is, where it is and how it was identified.
Offline HTML model built from the as-found record; here TS-4 is selected, showing 16 x 1492-WFB4, the outputs it carries, its measured position, the identification basis and the open carriers, with holds and observations pinned on the layout (site photos are withheld in the public sample).
INSIDE THE SAMPLE REPORT
Discuss your system →
Cover (page 1 of 20) Cover: eleven photos and one program backup, 14 findings, 4,012,164 bit checks with 0 mismatches.
Executive summary (page 2 of 20) The one page an owner needs: four severity-A findings and four decisions.
How we worked: stages and evidence register (page 4 of 20) The twelve stages and the evidence register: site photos, the program backup with its hash and one line from the plant PLC register.
Findings register (page 8 of 20) Every finding: what the logic does, why it matters, the recommended correction, and the evidence behind it.
Cause & effect matrix excerpt (page 13 of 20) The as-found C&E: every cause to every effect, rung-traced, defects included.
Verification (page 16 of 20) How the logic was proven, and a plain statement of what that does not prove.FITS INTO YOUR SYSTEMS
The package arrives on your standards and flows into the systems you already run: document control, change management, hazard studies, maintenance and training.
Drawings and documents issued on your numbering, title blocks and CAD standards.
Delivered into SharePoint or your document control system, with an index and revision status.
Each finding has a severity, the evidence and a recommended correction; most are tied to a functional test case, the rest to a FAT check or a field hold.
The as-found C&E and findings support hazard study revalidation with the behavior that actually runs.
The as-found device list feeds spares, lifecycle and obsolescence planning.
MP4 with captions, ready to load into your learning management system.
One HTML file in any browser. No install, no vendor license, no network calls.
NDA first. Work can stay on your machines. Nothing is published without your written approval.
PLATFORMS
RSLogix, Studio 5000, MicroLogix and SLC are trademarks of Rockwell Automation. DeltaV is a trademark of Emerson. No affiliation or endorsement is implied.
HOW AN ENGAGEMENT WORKS
Every engagement is scoped and priced in a written proposal before work begins. Deliverables, data handling, access and ownership are agreed there too.
One system. The essential understanding.
The Snapshot, plus everything your team needs to use it.
Many systems, one method and one register.
NDA first. We gather photos, the program backup and whatever documents exist, and agree the confidentiality boundary.
Program, as-found record and signals, each with its source and confidence.
Narrative, C&E, findings and the live model of the actual logic.
Walk the findings on the model with operations and engineering, and resolve the holds.
The package on your numbering, into your document control, with training videos for your LMS.
BEFORE YOU CHANGE IT
Bring the photos and the backup you already have.
We’ll show you what they can tell you.