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ML INFERENCE ENGINE FOR SWAT DASHBOARD
======================================
Real-time predictive maintenance inference using trained models.
Implements 3-stage pipeline:
- Stage 1: Anomaly Detection (ANY model from training)
- Stage 2: State Classification (ANY model from training)
- Stage 3: Component Identification (ANY model from training)
Models are automatically loaded based on final_config.json from each stage.
Models are cached for fast inference.
"""
import numpy as np
import pandas as pd
import pickle
import json
import warnings
from sensor_buffer import SensorBuffer
from alerts import trigger_alerts
warnings.filterwarnings('ignore')
try:
import tensorflow as tf
from tensorflow import keras
TF_AVAILABLE = True
except ImportError:
TF_AVAILABLE = False
print("β οΈ TensorFlow not available. Install: pip install tensorflow")
try:
import streamlit as st
STREAMLIT_AVAILABLE = False
except ImportError:
STREAMLIT_AVAILABLE = False
# ============================================================================
# CONFIGURATION
# ============================================================================
# Model paths (adjust these to your local paths)
MODEL_DIR = r"models"
DATA_DIR = r"ml_data"
# Component names (must match training)
COMPONENTS = ['P101', 'P201', 'P203', 'P205', 'P302', 'P402', 'P403', 'P501', 'MV101', 'MV304']
STATE_NAMES = ['ANOMALY', 'DEGRADING', 'FAULTED']
# ============================================================================
# MODEL LOADING (CACHED & GENERAL)
# ============================================================================
if STREAMLIT_AVAILABLE:
@st.cache_resource
def load_models():
"""Load all trained models (cached for performance)"""
return _load_models_internal()
else:
_cached_models = None
def load_models():
global _cached_models
if _cached_models is None:
_cached_models = _load_models_internal()
return _cached_models
def _load_models_internal():
"""Internal model loading function - GENERAL VERSION"""
models = {}
try:
# Load scaler
scaler_path = f"{DATA_DIR}/scaler.pkl"
with open(scaler_path, 'rb') as f:
models['scaler'] = pickle.load(f)
# ====================================================================
# STAGE 1: Load best model based on config
# ====================================================================
stage1_dir = f"{MODEL_DIR}/stage1"
with open(f"{stage1_dir}/final_config.json", "r") as f:
config1 = json.load(f)
models['stage1_type'] = config1['best_model_type']
if models['stage1_type'] in ['autoencoder', 'dae']:
# Autoencoder or Denoising Autoencoder
if not TF_AVAILABLE:
raise ImportError("TensorFlow required for autoencoder models")
model_file = 'autoencoder.keras' if models['stage1_type'] == 'autoencoder' else 'denoising_autoencoder.keras'
threshold_file = 'autoencoder_threshold.pkl' if models['stage1_type'] == 'autoencoder' else 'dae_threshold.pkl'
models['stage1'] = keras.models.load_model(f"{stage1_dir}/{model_file}", compile=False)
with open(f"{stage1_dir}/{threshold_file}", 'rb') as f:
models['stage1_threshold'] = pickle.load(f)
elif models['stage1_type'] == 'lof':
# Local Outlier Factor
with open(f"{stage1_dir}/lof.pkl", 'rb') as f:
models['stage1'] = pickle.load(f)
with open(f"{stage1_dir}/lof_threshold.pkl", 'rb') as f:
models['stage1_threshold'] = pickle.load(f)
elif models['stage1_type'] == 'iforest':
# Isolation Forest
with open(f"{stage1_dir}/isolation_forest.pkl", 'rb') as f:
models['stage1'] = pickle.load(f)
models['stage1_threshold'] = None # Uses built-in threshold
else: # xgboost
with open(f"{stage1_dir}/xgboost.pkl", 'rb') as f:
models['stage1'] = pickle.load(f)
# ===== FORCE CPU (XGBoost 3.1.0 SAFE) =====
m = models['stage1']
# sklearn wrapper params
try:
m.set_params(
device="cpu", # π₯ key line
tree_method="hist", # CPU-friendly
n_jobs=1 # avoid OpenMP fights
)
except Exception:
pass
# booster-level safety
try:
m.get_booster().set_param({"device": "cpu"})
except Exception:
pass
models['stage1_threshold'] = None
#print(" β
Stage 1 XGBoost loaded (CPU forced)")
# ====================================================================
# STAGE 2: Load best model based on config
# ====================================================================
stage2_dir = f"{MODEL_DIR}/stage2"
with open(f"{stage2_dir}/final_config.json", "r") as f:
config2 = json.load(f)
models['stage2_type'] = config2['best_model_type']
models['stage2_seq_length'] = config2.get('sequence_length', None)
if models['stage2_type'] in ['lstm', 'cnn']:
# Sequential models (LSTM or CNN)
if not TF_AVAILABLE:
raise ImportError("TensorFlow required for LSTM/CNN models")
models['stage2'] = keras.models.load_model(f"{stage2_dir}/{models['stage2_type']}.keras")
else: # xgboost
with open(f"{stage2_dir}/xgboost.pkl", 'rb') as f:
models['stage2'] = pickle.load(f)
# ====================================================================
# STAGE 3: Load best model based on config
# ====================================================================
stage3_dir = f"{MODEL_DIR}/stage3"
with open(f"{stage3_dir}/final_config.json", "r") as f:
config3 = json.load(f)
models['stage3_type'] = config3['best_model_type']
if models['stage3_type'] == 'mlp':
# Multi-Layer Perceptron
if not TF_AVAILABLE:
raise ImportError("TensorFlow required for MLP models")
models['stage3'] = keras.models.load_model(f"{stage3_dir}/mlp.keras")
elif models['stage3_type'] == 'lightgbm':
# LightGBM
with open(f"{stage3_dir}/lightgbm.pkl", 'rb') as f:
models['stage3'] = pickle.load(f)
else: # xgboost
with open(f"{stage3_dir}/xgboost.pkl", 'rb') as f:
models['stage3'] = pickle.load(f)
models['loaded'] = True
print(f"β
Models loaded successfully!")
print(f" Stage 1: {config1['best_model']} ({models['stage1_type']})")
print(f" Stage 2: {config2['best_model']} ({models['stage2_type']})")
print(f" Stage 3: {config3['best_model']} ({models['stage3_type']})")
return models
except Exception as e:
print(f"β οΈ Error loading models: {e}")
models['loaded'] = False
models['error'] = str(e)
return models
# ============================================================================
# FEATURE EXTRACTION
# ============================================================================
def extract_features(payload):
"""
Extract 40 features from payload (matches training format).
Returns:
np.array: (1, 40) feature array
"""
features = []
# ========================================================================
# 16 SENSOR READINGS
# ========================================================================
sensors = [
'true_FIT101', 'true_FIT201', 'true_FIT301', 'true_FIT401', 'true_FIT501',
'true_LIT101', 'true_LIT301', 'true_LIT401',
'true_AIT201', 'true_AIT202', 'true_AIT203', 'true_AIT401', 'true_AIT402', 'true_AIT501',
'true_DPIT301', 'true_PIT501'
]
for sensor in sensors:
val = payload.get(sensor, 0)
try:
features.append(float(val))
except:
features.append(0.0)
# ========================================================================
# 24 MOTOR PHYSICS FEATURES
# ========================================================================
# These should match the motor physics features used in training
# Format: motor_temp, current, vibration for each component
components = ['P101', 'P201', 'P203', 'P205', 'P302', 'P402', 'P403', 'P501']
for comp in components:
# Get motor physics features from payload
temp_key = f'true_{comp}_motor_temp'
current_key = f'true_{comp}_current'
vib_key = f'true_{comp}_vibration'
# Extract values (use defaults if not present)
temp = payload.get(temp_key, 0.0)
current = payload.get(current_key, 0.0)
vib = payload.get(vib_key, 0.0)
try:
features.extend([float(temp), float(current), float(vib)])
except:
features.extend([0.0, 0.0, 0.0])
# Convert to numpy array
return np.array(features).reshape(1, -1)
# ============================================================================
# STAGE 1: ANOMALY DETECTION (GENERAL)
# ============================================================================
def predict_anomaly(features_scaled, models):
"""
Stage 1: Binary anomaly detection using ANY model type.
Returns:
tuple: (is_anomaly, confidence, score)
"""
if not models.get('loaded'):
return False, 0.0, 0.0
try:
model_type = models['stage1_type']
# ====================================================================
# AUTOENCODER / DENOISING AUTOENCODER
# ====================================================================
if model_type in ['autoencoder', 'dae']:
# Reconstruct input
reconstructed = models['stage1'].predict(features_scaled, verbose=0)
# Compute reconstruction error (MSE)
error = np.mean((features_scaled - reconstructed) ** 2)
# Compare to threshold
threshold = models['stage1_threshold']
is_anomaly = (error > threshold)
# Compute confidence
if is_anomaly:
confidence = min(1.0, (error / threshold - 1.0) * 2 + 0.5)
else:
confidence = min(1.0, (1.0 - error / threshold) + 0.5)
return bool(is_anomaly), float(confidence), float(error)
# ====================================================================
# LOCAL OUTLIER FACTOR
# ====================================================================
elif model_type == 'lof':
# Get anomaly score (higher = more anomalous)
score = -models['stage1'].decision_function(features_scaled)[0]
threshold = models['stage1_threshold']
is_anomaly = (score > threshold)
# Confidence based on distance from threshold
if is_anomaly:
confidence = min(1.0, (score / threshold - 1.0) + 0.5)
else:
confidence = min(1.0, (1.0 - score / threshold) + 0.5)
return bool(is_anomaly), float(confidence), float(score)
# ====================================================================
# ISOLATION FOREST
# ====================================================================
elif model_type == 'iforest':
# Predict (-1 = anomaly, 1 = normal)
pred = models['stage1'].predict(features_scaled)[0]
is_anomaly = (pred == -1)
# Get anomaly score for confidence
score = -models['stage1'].score_samples(features_scaled)[0]
confidence = min(1.0, abs(score) / 2.0)
return bool(is_anomaly), float(confidence), float(score)
# ====================================================================
# XGBOOST
# ====================================================================
else: # xgboost
import xgboost as xgb
import numpy as np
# force CPU
try:
models["stage1"].set_params(device="cpu", tree_method="hist", n_jobs=1)
except Exception:
pass
try:
models["stage1"].get_booster().set_param({"device": "cpu"})
except Exception:
pass
x = np.ascontiguousarray(features_scaled.astype(np.float32))
dm = xgb.DMatrix(x)
p1 = float(models["stage1"].get_booster().predict(dm)[0]) # binary:logistic => P(class=1)
is_anomaly = p1 > 0.5
confidence = p1 if is_anomaly else (1.0 - p1)
return bool(is_anomaly), float(confidence), float(p1)
except Exception as e:
print(f"Stage 1 error: {e}")
return False, 0.0, 0.0
# ============================================================================
# STAGE 2: STATE CLASSIFICATION (GENERAL)
# ============================================================================
def predict_state(features_scaled, models, is_anomaly, sensor_buffer=None):
"""
Stage 2: Multi-class state classification using ANY model type.
Only runs if Stage 1 detected anomaly.
Args:
features_scaled: Current sample features (scaled)
models: Loaded models dict
is_anomaly: Whether Stage 1 detected anomaly
sensor_buffer: Optional SensorBuffer for LSTM/CNN
Returns:
tuple: (state_name, confidence, state_probs)
"""
if not is_anomaly:
return "NORMAL", 1.0, [0.0, 0.0, 0.0]
if not models.get('loaded'):
return "UNKNOWN", 0.0, [0.0, 0.0, 0.0]
try:
model_type = models['stage2_type']
# ====================================================================
# LSTM / CNN (Sequential models)
# ====================================================================
if model_type in ['lstm', 'cnn']:
seq_length = models['stage2_seq_length']
# NEW: Try to use buffer if available
if sensor_buffer is not None and sensor_buffer.is_ready():
# Use real sequence from buffer
seq = sensor_buffer.get_sequence()
seq = seq.reshape(1, seq_length, -1)
use_buffer = True
else:
# Fallback: Repeat current sample (old hack)
seq = np.repeat(features_scaled, seq_length, axis=0)
seq = seq.reshape(1, seq_length, -1)
use_buffer = False
# Predict
probs = models['stage2'].predict(seq, verbose=0)[0]
# Get predicted class
state_idx = int(np.argmax(probs))
state_name = STATE_NAMES[state_idx]
confidence = float(probs[state_idx])
# Reduce confidence if using fallback hack
if not use_buffer:
confidence *= 0.85 # Penalty for not having real sequence
return state_name, confidence, probs.tolist()
# ====================================================================
# XGBOOST (Tabular model - doesn't need buffer)
# ====================================================================
else: # xgboost
# Predict probabilities
probs = models['stage2'].predict_proba(features_scaled)[0]
# Get predicted class
state_idx = int(np.argmax(probs))
state_name = STATE_NAMES[state_idx]
confidence = float(probs[state_idx])
return state_name, confidence, probs.tolist()
except Exception as e:
print(f"Stage 2 error: {e}")
return "UNKNOWN", 0.0, [0.0, 0.0, 0.0]
# ============================================================================
# STAGE 3: COMPONENT IDENTIFICATION (GENERAL)
# ============================================================================
def predict_component(features_scaled, models, state_name):
"""
Stage 3: Component identification using ANY model type.
Only runs if state is DEGRADING or FAULTED.
Returns:
tuple: (component, confidence, top3_components)
"""
if state_name == "NORMAL":
return None, 0.0, []
if not models.get('loaded'):
return None, 0.0, []
try:
model_type = models['stage3_type']
# ====================================================================
# MLP (Neural Network)
# ====================================================================
if model_type == 'mlp':
# Predict probabilities
probs = models['stage3'].predict(features_scaled, verbose=0)[0]
# Get top prediction
comp_idx = int(np.argmax(probs))
component = COMPONENTS[comp_idx]
confidence = float(probs[comp_idx])
# Get top 3
top3_idx = np.argsort(probs)[-3:][::-1]
top3 = [(COMPONENTS[i], float(probs[i])) for i in top3_idx]
return component, confidence, top3
# ====================================================================
# LIGHTGBM or XGBOOST
# ====================================================================
else: # lightgbm or xgboost
# Predict probabilities
probs = models['stage3'].predict_proba(features_scaled)[0]
# Get top prediction
comp_idx = int(np.argmax(probs))
component = COMPONENTS[comp_idx]
confidence = float(probs[comp_idx])
# Get top 3
top3_idx = np.argsort(probs)[-3:][::-1]
top3 = [(COMPONENTS[i], float(probs[i])) for i in top3_idx]
return component, confidence, top3
except Exception as e:
print(f"Stage 3 error: {e}")
return None, 0.0, []
# ============================================================================
# FULL PIPELINE
# ============================================================================
def run_pipeline(payload, sensor_buffer=None):
"""
Run complete 3-stage ML pipeline on payload.
Args:
payload (dict): Raw sensor/actuator data from dashboard
sensor_buffer (SensorBuffer): Optional buffer for LSTM/CNN models
Returns:
dict: Prediction results with all stages
"""
# Load models (cached)
models = load_models()
# Check if models loaded successfully
if not models.get('loaded'):
return {
'success': False,
'error': models.get('error', 'Models not loaded'),
'stage1': {'is_anomaly': False, 'confidence': 0.0},
'stage2': {'state': 'UNKNOWN', 'confidence': 0.0},
'stage3': {'component': None, 'confidence': 0.0}
}
try:
# Extract features
features = extract_features(payload)
# Scale features
features_scaled = models['scaler'].transform(features)
# NEW: Add to buffer if provided
if sensor_buffer is not None:
sensor_buffer.add_sample(features_scaled[0]) # Add 1D array
# Stage 1: Anomaly Detection
is_anomaly, s1_conf, score = predict_anomaly(features_scaled, models)
# Stage 2: State Classification (NOW WITH BUFFER)
state, s2_conf, state_probs = predict_state(
features_scaled,
models,
is_anomaly,
sensor_buffer=sensor_buffer # PASS BUFFER
)
# Stage 3: Component Identification
component, s3_conf, top3 = predict_component(features_scaled, models, state)
# Compile results
result = {
'success': True,
'timestamp': pd.Timestamp.now(),
'stage1': {
'is_anomaly': is_anomaly,
'confidence': s1_conf,
'score': score,
'model_type': models['stage1_type']
},
'stage2': {
'state': state,
'confidence': s2_conf,
'probabilities': {
'ANOMALY': state_probs[0] if len(state_probs) > 0 else 0.0,
'DEGRADING': state_probs[1] if len(state_probs) > 1 else 0.0,
'FAULTED': state_probs[2] if len(state_probs) > 2 else 0.0
},
'model_type': models['stage2_type']
},
'stage3': {
'component': component,
'confidence': s3_conf,
'top3': top3,
'model_type': models['stage3_type']
}
}
# NEW: Add buffer status to result
if sensor_buffer is not None:
result['buffer_status'] = {
'size': sensor_buffer.size(),
'ready': sensor_buffer.is_ready(),
'using_buffer': sensor_buffer.is_ready() and models['stage2_type'] in ['lstm', 'cnn']
}
# Build component health + recommended actions
component_health = get_component_health(result)
result['component_health'] = component_health # optional (for dashboard)
result['actions'] = get_recommended_actions(result, component_health)
# Now trigger alerts (email uses result['actions'])
alert_status = trigger_alerts(result)
result['alerts_sent'] = alert_status
return result
except Exception as e:
return {
'success': False,
'error': str(e),
'stage1': {'is_anomaly': False, 'confidence': 0.0},
'stage2': {'state': 'ERROR', 'confidence': 0.0},
'stage3': {'component': None, 'confidence': 0.0}
}
# ============================================================================
# COMPONENT HEALTH SUMMARY
# ============================================================================
def get_component_health(prediction):
"""
Generate health status for all components.
Returns:
dict: {component_name: status_dict}
"""
health = {}
state = prediction['stage2']['state']
identified_comp = prediction['stage3']['component']
top3 = prediction['stage3'].get('top3', [])
for comp in COMPONENTS:
if state == "NORMAL":
health[comp] = {
'status': 'NORMAL',
'icon': 'π’',
'confidence': 1.0,
'message': 'Operating normally'
}
elif comp == identified_comp:
# Primary suspect
conf = prediction['stage3']['confidence']
if state == "FAULTED":
health[comp] = {
'status': 'FAULTED',
'icon': 'π΄',
'confidence': conf,
'message': f'FAULTED - Immediate action required'
}
elif state == "DEGRADING":
health[comp] = {
'status': 'DEGRADING',
'icon': 'π‘',
'confidence': conf,
'message': f'Degrading - Schedule maintenance'
}
elif state == "ANOMALY":
health[comp] = {
'status': 'MONITOR',
'icon': 'π ',
'confidence': conf,
'message': 'Anomaly detected - Monitor closely'
}
elif any(comp == t[0] for t in top3):
# In top 3 - possible suspect
conf = next(t[1] for t in top3 if t[0] == comp)
health[comp] = {
'status': 'MONITOR',
'icon': 'π ',
'confidence': conf,
'message': f'Check (Top-3: {conf*100:.0f}%)'
}
else:
# Not identified
health[comp] = {
'status': 'NORMAL',
'icon': 'π’',
'confidence': 0.0,
'message': 'Operating normally'
}
return health
# ============================================================================
# RECOMMENDED ACTIONS
# ============================================================================
def get_recommended_actions(prediction, component_health):
"""
Generate maintenance recommendations based on predictions.
Returns:
list: List of action strings
"""
actions = []
state = prediction['stage2']['state']
component = prediction['stage3']['component']
if state == "NORMAL":
actions.append("β
System operating normally - No action required")
return actions
else:
if state != "FAULTED" and state != "DEGRADING":
actions.append(f"β οΈ Suspected component: {component}")
if component:
# Component-specific actions
comp_actions = {
'P101': [
'π§ Inspect intake pump P101 for wear',
'π Check pump vibration and bearing temperature',
'π§ Verify intake flow rate and pressure'
],
'P201': [
'π§ Inspect NaCl dosing pump P201',
'π Check chemical feed lines for blockages',
'βοΈ Verify NaCl concentration and flow rate'
],
'P203': [
'π§ Inspect HCl dosing pump P203',
'π Check acid feed system for leaks',
'βοΈ Calibrate pH sensor AIT202'
],
'P205': [
'π§ Inspect NaOCl dosing pump P205',
'π Check chlorine feed system',
'βοΈ Verify ORP readings (AIT203)'
],
'P302': [
'π§ Inspect UF feed pump P302',
'π Check UF membrane differential pressure',
'π§ Consider membrane backwash or cleaning'
],
'P402': [
'π§ Inspect dechlorination feed pump P402',
'π Check UV system operation',
'βοΈ Verify ORP levels post-UV'
],
'P403': [
'π§ Inspect NaHSOβ dosing pump P403',
'π Check dechlorination efficiency',
'βοΈ Verify residual chlorine levels'
],
'P501': [
'π§ Inspect RO feed pump P501',
'π Check RO membrane pressure and flow',
'π§ Monitor permeate quality (TDS)'
],
'MV101': [
'π§ Inspect motorized valve MV101',
'π Check valve position and response',
'βοΈ Lubricate valve actuator'
],
'MV304': [
'π§ Inspect motorized valve MV304',
'π Check UF backwash valve operation',
'βοΈ Verify valve seating'
]
}
if state == "FAULTED":
actions.append(f"π¨ URGENT: {component} has FAULTED")
actions.append("π Alert maintenance team")
actions.append(f"βΈοΈ Consider stopping {component} immediately")
# General actions based on state
if state == "DEGRADING":
actions.append(f"π¨ URGENT: {component} is DEGRADING")
actions.append("π
Schedule maintenance within next 24-48 hours")
actions.append("π Increase monitoring frequency")
if component in comp_actions:
actions.extend(comp_actions[component][:3]) # Top 3 actions
return actions
# ============================================================================
# TESTING
# ============================================================================
if __name__ == "__main__":
print("\n" + "=" * 60)
print("TEST 1: Without Buffer (Old Way)")
print("=" * 60)
test_payload = {
'true_FIT101': 2.5, 'true_LIT101': 800.0,
'true_FIT201': 2.3, 'true_AIT201': 150.0, 'true_AIT202': 7.2, 'true_AIT203': 350.0,
'true_FIT301': 2.1, 'true_LIT301': 750.0, 'true_DPIT301': 0.15,
'true_FIT401': 2.0, 'true_LIT401': 700.0, 'true_AIT401': 85.0, 'true_AIT402': 280.0,
'true_FIT501': 1.8, 'true_PIT501': 5.2, 'true_AIT501': 6.8,
# Motor physics features
'true_P101_motor_temp': 45.0, 'true_P101_current': 3.5, 'true_P101_vibration': 1.2,
'true_P201_motor_temp': 42.0, 'true_P201_current': 2.8, 'true_P201_vibration': 0.9,
'true_P203_motor_temp': 40.0, 'true_P203_current': 2.5, 'true_P203_vibration': 0.8,
'true_P205_motor_temp': 43.0, 'true_P205_current': 3.0, 'true_P205_vibration': 1.0,
'true_P302_motor_temp': 46.0, 'true_P302_current': 3.8, 'true_P302_vibration': 1.3,
'true_P402_motor_temp': 44.0, 'true_P402_current': 3.2, 'true_P402_vibration': 1.1,
'true_P403_motor_temp': 41.0, 'true_P403_current': 2.7, 'true_P403_vibration': 0.9,
'true_P501_motor_temp': 48.0, 'true_P501_current': 4.0, 'true_P501_vibration': 1.4,
'true_MV101_motor_temp': 38.0, 'true_MV101_current': 1.5, 'true_MV101_vibration': 0.5,
'true_MV304_motor_temp': 39.0, 'true_MV304_current': 1.6, 'true_MV304_vibration': 0.6,
}
# Create buffer and add 60 samples
buffer = SensorBuffer(window_size=60, n_features=40)
for i in range(60):
result1 = run_pipeline(test_payload, sensor_buffer=buffer)
if result1['success']:
print(f"β
Stage 1: {result1['stage1']['is_anomaly']}")
print(f"β
Stage 2: {result1['stage2']['state']} (conf: {result1['stage2']['confidence']:.2f})")
print(f"β
Stage 3: {result1['stage3']['component']}")
print(f"\nπ Buffer Status:")
print(f" Size: {result1['buffer_status']['size']}/60")
print(f" Ready: {result1['buffer_status']['ready']}")
print(f" Using Buffer: {result1['buffer_status']['using_buffer']}")
else:
print(f"\nβ Pipeline Error: {result1['error']}")
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