Hale Engineering completed an industrial OT network survey after frequent shutdowns were linked to an unlabelled, undocumented network. Engineers traced every network cable, identified connected devices and IP addresses, and produced a clear network diagram and report. Following the project, routine maintenance no longer caused accidental plant shutdowns.
Project Overview 
The network linked factory-floor PLC and SCADA systems with main-office computers through managed switches, TP-Link converters, copper and fibre cabling. It also included network cabinets, patch panels, an uninterruptible power supply and infrastructure associated with the Continuous Emissions Monitoring System (CEMS).
Operational Challenge and Risks
The network lacked consistent cable labels and accurate diagrams. Engineers also discovered unexpected connections unknown to site personnel.
When equipment or a connection failed, the client could not quickly locate the problem. Simple maintenance could disturb an unidentified connection, turning a minor task into a major outage and contributing to frequent shutdowns.
Engineering Assessment
Hale Engineering established the network’s “as-found” condition: its arrangement at the time of inspection. Engineers hand-traced every network cable and device within the project scope from end to end across the site.
Network discovery software identified connected machines and their IP addresses. Combining this information with the physical survey revealed missing labels, undocumented links and relationships between factory-floor and office equipment.
Hale Engineering’s Industrial OT Network Survey
The work included:
- inspecting network equipment and cabinets;
- tracing and recording cables and connected devices;
- identifying connected machines and IP addresses;
- documenting previously unknown connections; and
- producing an easy-to-read network diagram and report.
Equipment and Network Strategy
This was a survey and documentation project, not a network upgrade. No physical equipment or software changes were made. The approach created an accurate technical baseline for maintenance, fault finding and future network planning.
Live-Plant Survey, Safety and Verification
A key challenge was tracing the network across a live, operating plant without stopping production. Hale Engineering inspected live electrical and control cabinets while following strict site safety procedures and taking care not to interrupt operational connections.
As no equipment or configuration changes were made, post-modification testing and commissioning were not applicable. Physical tracing and software-discovered information were combined to form the final diagram.
Results and Operational Benefits
The client received a complete network map and report, improving visibility of the existing architecture and giving maintenance teams a practical reference before starting work.
Most importantly, regular maintenance no longer caused accidental plant shutdowns following completion. The documentation also provides a clearer basis for future fault investigation, although no measured reduction in diagnostic time or total downtime has been claimed.
Why This Engineering Approach Matters
Unlabelled industrial networks can turn small faults and maintenance activities into extended production interruptions. The NCSC recommends documenting connectivity between assets within operational technology systems. An industrial OT network survey brings cable routes, connected devices and IP information into one dependable record, supporting better-informed maintenance decisions.
Frequently Asked Questions
What is an OT network survey?
It documents the devices, cables and communication routes supporting operational plant systems.
Why record cables and IP addresses?
Together, they show physical connections and the devices communicating across the network.
Did Hale Engineering upgrade the network?
No. The confirmed scope covered surveying, mapping and reporting only.
What result was achieved?
Routine maintenance no longer caused accidental plant shutdowns after the project.
If your plant has undocumented network connections or maintenance-related communication problems, Hale Engineering can provide a clear industrial OT network survey and technical report to support informed engineering decisions.