Service Catalogue
Six rungs, each one proven in the field
The six services below cover the full arc of a control project. Read them as a sequence, because that is how they are sold and delivered. A client can enter at any rung, and the same engineer will draw the loop, wire the terminal and sign the commissioning sheet.
SERVICE 01
Control System Architecture Design
Architecture is the discipline of deciding what the system must do before anyone chooses the hardware. BarnettWorks develops the sequence of operations from interviews with operations and maintenance, then builds a cause and effect matrix that names every input, every output and every interlock. From there we produce a basis of design document, a device list, an I/O schedule and a network topology drawing that shows exactly how controllers, remote racks, drives, safety relays and the SCADA node speak to one another.
The architecture package also fixes the safety concept. We identify hazards, recommend the safety integrity approach, and separate safety functions from standard control so the design stays clear under review. Controller selection, scan time budget, redundancy decisions and network segmentation are all argued in writing, with the tradeoffs stated so your team can approve them with full information. The result is a design a plant engineer, an insurer and a maintenance electrician can each read without asking for an oral explanation.
Every architecture carries a wiring philosophy. We define wire numbering, terminal numbering, color conventions and shield grounding rules up front so the panel shop and the electrical contractor follow one standard rather than inventing three. That single decision saves weeks of confusion at commissioning and prevents the classic failure where the drawing says one thing and the cabinet says another.
SERVICE 02
PLC and SCADA Integration
Integration is where the paper design becomes running code and a screen an operator can trust. Our programmers write structured ladder logic and function block diagrams against the approved sequence of operations, using a consistent tag naming convention so that a point found in the SCADA database can be located in the logic within seconds. We configure communication paths from processor to HMI to historian, verify timing under realistic load, and test each faceplate with simulated and then live signals.
SCADA work is judged by what happens at three in the morning when a line trips. We build operator screens around task flow rather than around the device list, put the critical alarms on the first layer, and rationalize the alarm database so nuisance chatter is removed before it ever reaches an operator. Trend groups, setpoint management and historical logging are engineered so the data a process engineer needs is already recorded when a quality question arrives. Every screen links to the interlock that governs it, and every interlock has a documented test.
We also handle the unglamorous integration work that decides whether a project succeeds. ControlLogix, S7 and Modbus TCP networks are segmented and documented. Managed switch configuration, VLAN separation and firewall rules are recorded so your information technology team can audit them. Drive parameters are exported and archived. Version control is applied to the program files, so a future change can always be compared against the revision that was commissioned and signed.
SERVICE 03
Panel Fabrication Supervision
A control panel is a small building with its own power distribution, its own layout and its own documentation, and BarnettWorks treats it that way. We produce the panel layout, the backplate drilling schedule, the power distribution drawing, the terminal schedule and the full wire number list. The fabricator builds against our package, and our engineer witnesses the build at defined hold points so problems are caught while they are still cheap to fix.
Continuity testing is performed point to point against the wire list, not sampled. We verify breaker ratings, fusing, surge protection, grounding and shield terminations. Labels are inspected for legibility and consistency because an unlabeled terminal is a future outage. Before shipment we witness the functional test, record the results on the project test sheet, and photograph the panel interior so the as built record reflects the cabinet as it truly left the shop.
Spare capacity is engineered deliberately. We confirm that spare I/O, spare terminal blocks and spare breaker poles are present in the quantity your standard requires, and we document exactly where each spare lives. When the plant later adds an instrument, the electrician does not have to guess where the spare landed. The documentation already says which terminal, which card and which fuse protect it.
SERVICE 04
Commissioning and Field Testing
Commissioning is where drawings meet dirt, and this is the rung BarnettWorks is proudest of. Our engineers loop check every instrument from the field device to the processor, verify rotation direction and valve stroke, confirm scaling and units, and tune control loops so the process holds its setpoint instead of hunting around it. Interlocks are proven functionally, with the initiated action and the observed result recorded on a signed test sheet rather than summarized in an email.
The field team works beside the electrical contractor and the operations crew. Handover is a working session, not a folder left on a desk. We walk operators through the screens they will use, demonstrate the alarm response, and capture their corrections while the system is still open for change. Any deviation between design and reality is resolved on the spot and the drawing is revised the same week, so the as built set is accurate on the day of turnover.
Where production windows are tight, commissioning is planned in controlled phases with pre-agreed go and no-go checks. Each phase ends with a written status, a list of open punch items and a clear statement of what is proven and what remains. A loop is closed only when the process variable moves the way the sequence of operations requires and the operator confirms it moved that way.
SERVICE 05
Legacy System Retrofits
Older lines rarely get the luxury of a long shutdown, so BarnettWorks migrates legacy control one island at a time. We begin by reverse engineering what exists, including panels that have no drawings, producing an accurate I/O map and a written description of current process behavior before proposing a single new component. The old system keeps running in parallel while the new architecture is proven off line.
Cutover happens during a planned window with a rollback plan written before the first wire is moved. Our engineers reproduce the process behavior closely enough that operators recognize the line after the change, while the plant gains modern diagnostics, remote access and spare parts that can actually be purchased. Obsolete processors, discontinued drives and unsupported operator panels are retired in a sequence that spreads risk across several short windows rather than concentrating it into one long outage.
Retrofit documentation receives special attention because the value of the project is the recoverable knowledge. Old wire numbers are mapped to new wire numbers, old tag names are mapped to new tag names, and a cross reference table ships with the turnover package. Years later, an electrician holding an original drawing can find the equivalent point in the modern system without repeating the reverse engineering effort.
SERVICE 06
24/7 Support Contracts
A control system is a living asset, and BarnettWorks support contracts give it a named owner. Each account receives a designated engineer, a defined response window, and remote diagnostics access into the controller and the SCADA node. When a fault occurs, the plant speaks to someone who has already read the drawings rather than to a call centre reading a script, and that difference is measured in minutes of downtime.
We keep the as built drawings current as changes happen, train the maintenance team on the systems they own, and review alarm history and fault logs each quarter to find the problems that keep returning. Recurring faults are treated as engineering findings, not as noise to be silenced, and the recommended correction is presented with the evidence behind it. The support relationship also protects the investment in the original design by keeping the documentation as valuable as the hardware.
Support plans scale with the site. A single line can be covered with a remote diagnostic agreement and an annual review. A multi area plant can add scheduled site visits, spare parts management and an annual commissioning style audit of critical loops. Whatever the scope, the contract states the response window, the coverage hours and the escalation path in plain language, so expectations are settled before an emergency rather than during one.