app.py

import streamlit as st
import numpy as np
import pandas as pd
import plotly.graph_objects as go
from plotly.subplots import make_subplots
import time

# =====================================================
# PAGE CONFIGURATION
# =====================================================

# =====================================================
# FIX FOR STREAMLIT CLOUD / HUGGING FACE
# =====================================================

st.set_page_config(
    page_title="Industrial PLC-DCS-SCADA Simulator",
    layout="wide"
)

st.title("🏭 Industrial Chemical Plant Simulator")
st.markdown("## PLC + DCS + SCADA Integrated Control System")

# =====================================================
# SIDEBAR
# =====================================================

st.sidebar.header("Plant Parameters")

setpoint = st.sidebar.slider(
    "Reactor Temperature Setpoint",
    40,
    120,
    80
)

simulation_time = st.sidebar.slider(
    "Simulation Time",
    100,
    500,
    250
)

noise = st.sidebar.slider(
    "Sensor Noise",
    0.0,
    2.0,
    0.3
)

# =====================================================
# PROCESS MODEL
# =====================================================

ambient_temp = 25
process_gain = 0.12
cooling_gain = 0.20
thermal_mass = 18

# =====================================================
# PLC TAGS
# =====================================================

class PLC:

    def __init__(self):
        self.tags = {
            "TT101": 0,
            "CV101": 0,
            "SP101": setpoint,
            "ALARM_HIGH": False,
            "PUMP_RUN": True
        }

    def update(self, temperature, valve):
        self.tags["TT101"] = temperature
        self.tags["CV101"] = valve

        if temperature > setpoint + 10:
            self.tags["ALARM_HIGH"] = True
        else:
            self.tags["ALARM_HIGH"] = False

# =====================================================
# CONTROL SIMULATION
# =====================================================

def simulate(controller):

    plc = PLC()

    temp = 30
    integral = 0
    previous_error = 0

    temperatures = []
    valves = []
    alarms = []
    times = []

    for t in range(simulation_time):

        error = setpoint - temp

        # =============================================
        # PLC + ON/OFF CONTROL
        # =============================================

        if controller == "ONOFF":

            if temp < setpoint:
                valve = 0
            else:
                valve = 100

        # =============================================
        # PLC + PID CONTROL
        # =============================================

        elif controller == "PID":

            kp = 2.5
            ki = 0.04
            kd = 0.7

            integral += error
            derivative = error - previous_error

            valve = kp * error + ki * integral + kd * derivative
            valve = np.clip(valve, 0, 100)

            previous_error = error

        # =============================================
        # PLC + MPC CONTROL
        # =============================================

        elif controller == "MPC":

            future_error = error * 0.85
            valve = 1.8 * future_error + 25
            valve = np.clip(valve, 0, 100)

        # =============================================
        # PROCESS DYNAMICS
        # =============================================

        heating = process_gain * (100 - temp)
        cooling = cooling_gain * (valve / 100) * (temp - ambient_temp)

        dT = (heating - cooling) / thermal_mass

        temp += dT + np.random.normal(0, noise)

        # PLC UPDATE
        plc.update(temp, valve)

        temperatures.append(temp)
        valves.append(valve)
        alarms.append(plc.tags["ALARM_HIGH"])
        times.append(t)

    return pd.DataFrame({
        "Time": times,
        "Temperature": temperatures,
        "Valve": valves,
        "Alarm": alarms
    })

# =====================================================
# RUN ALL CONTROLLERS
# =====================================================

onoff_df = simulate("ONOFF")
pid_df = simulate("PID")
mpc_df = simulate("MPC")

# =====================================================
# SCADA HEADER
# =====================================================

st.markdown("---")

sc1, sc2, sc3, sc4 = st.columns(4)

with sc1:
    st.metric("Plant Status", "RUNNING")

with sc2:
    st.metric("PLC Status", "ONLINE")

with sc3:
    st.metric("DCS Network", "CONNECTED")

with sc4:
    st.metric("SCADA", "ACTIVE")

# =====================================================
# SECTION 1 : PLC + ON-OFF CONTROL
# =====================================================

st.markdown("---")
st.header("🟢 SECTION 1 : PLC + ON-OFF CONTROL")
import streamlit as st
import numpy as np
import pandas as pd
import plotly.graph_objects as go
from plotly.subplots import make_subplots
import time

# -------------------------------------------------
# PAGE CONFIG
# -------------------------------------------------

st.set_page_config(
    page_title="Chemical Plant Control Simulator",
    layout="wide"
)

st.title("🏭 Chemical Plant DCS / SCADA Simulator")
st.markdown("### Temperature Control of a Chemical Reactor")

# -------------------------------------------------
# SIDEBAR
# -------------------------------------------------

st.sidebar.header("Simulation Settings")

setpoint = st.sidebar.slider(
    "Temperature Setpoint (°C)",
    40,
    120,
    80
)

simulation_time = st.sidebar.slider(
    "Simulation Time",
    50,
    500,
    200
)

noise_level = st.sidebar.slider(
    "Process Noise",
    0.0,
    2.0,
    0.3
)

# -------------------------------------------------
# PROCESS MODEL
# -------------------------------------------------

ambient_temp = 25
process_gain = 0.12
cooling_gain = 0.18
thermal_mass = 18

# -------------------------------------------------
# SIMULATION FUNCTION
# -------------------------------------------------

def simulate(controller_type):

    temp = 30
    integral = 0
    previous_error = 0

    temperatures = []
    valve_positions = []
    times = []

    for t in range(simulation_time):

        error = setpoint - temp

        # -----------------------------------------
        # ON-OFF CONTROL
        # -----------------------------------------
        if controller_type == "ON-OFF":

            if temp < setpoint:
                valve = 0
            else:
                valve = 100

        # -----------------------------------------
        # PID CONTROL
        # -----------------------------------------
        elif controller_type == "PID":

            kp = 2.5
            ki = 0.05
            kd = 0.8

            integral += error
            derivative = error - previous_error

            valve = (
                kp * error
                + ki * integral
                + kd * derivative
            )

            valve = np.clip(valve, 0, 100)

            previous_error = error

        # -----------------------------------------
        # MPC-LIKE CONTROL
        # -----------------------------------------
        elif controller_type == "MPC":

            future_error = error * 0.85
            valve = 1.8 * future_error + 25
            valve = np.clip(valve, 0, 100)

        # -----------------------------------------
        # PROCESS DYNAMICS
        # -----------------------------------------

        heating = process_gain * (100 - temp)
        cooling = cooling_gain * (valve / 100) * (temp - ambient_temp)

        dT = (heating - cooling) / thermal_mass

        temp += dT + np.random.normal(0, noise_level)

        temperatures.append(temp)
        valve_positions.append(valve)
        times.append(t)

    return pd.DataFrame({
        "Time": times,
        "Temperature": temperatures,
        "Valve": valve_positions
    })

# -------------------------------------------------
# RUN SIMULATIONS
# -------------------------------------------------

onoff_df = simulate("ON-OFF")
pid_df = simulate("PID")
mpc_df = simulate("MPC")

# -------------------------------------------------
# LIVE SCADA CARDS
# -------------------------------------------------

col1, col2, col3 = st.columns(3)

latest_onoff = round(onoff_df["Temperature"].iloc[-1], 2)
latest_pid = round(pid_df["Temperature"].iloc[-1], 2)
latest_mpc = round(mpc_df["Temperature"].iloc[-1], 2)

with col1:
    st.metric("ON-OFF Temp", f"{latest_onoff} °C")

with col2:
    st.metric("PID Temp", f"{latest_pid} °C")

with col3:
    st.metric("MPC Temp", f"{latest_mpc} °C")

# -------------------------------------------------
# DCS STYLE REACTOR DIAGRAM
# -------------------------------------------------

st.markdown("---")
st.subheader("⚙️ Reactor DCS Overview")

reactor_col1, reactor_col2 = st.columns([2, 1])

with reactor_col1:

    fig_reactor = go.Figure()

    fig_reactor.add_shape(
        type="rect",
        x0=1,
        y0=1,
        x1=4,
        y1=8,
        line=dict(color="cyan", width=4),
        fillcolor="rgba(0,255,255,0.1)"
    )

    fig_reactor.add_annotation(
        x=2.5,
        y=4.5,
        text=f"Reactor\nSP = {setpoint}°C",
        showarrow=False,
        font=dict(size=18)
    )

    fig_reactor.add_shape(
        type="line",
        x0=4,
        y0=4,
        x1=7,
        y1=4,
        line=dict(color="orange", width=8)
    )

    fig_reactor.add_annotation(
        x=6,
        y=4.5,
        text="Cooling Water",
        showarrow=False
    )

    fig_reactor.update_layout(
        height=400,
        paper_bgcolor="black",
        plot_bgcolor="black",
        font_color="white",
        xaxis=dict(visible=False),
        yaxis=dict(visible=False)
    )

    st.plotly_chart(fig_reactor, use_container_width=True)

with reactor_col2:

    gauge = go.Figure(go.Indicator(
        mode="gauge+number",
        value=latest_pid,
        title={'text': "PID Reactor Temp"},
        gauge={
            'axis': {'range': [None, 120]},
            'bar': {'color': "red"},
            'steps': [
                {'range': [0, 60], 'color': "lightgreen"},
                {'range': [60, 90], 'color': "yellow"},
                {'range': [90, 120], 'color': "orange"}
            ]
        }
    ))

    gauge.update_layout(height=400)

    st.plotly_chart(gauge, use_container_width=True)

# -------------------------------------------------
# TEMPERATURE COMPARISON
# -------------------------------------------------

st.markdown("---")
st.subheader("📈 Temperature Response Comparison")

fig = go.Figure()

fig.add_trace(go.Scatter(
    x=onoff_df["Time"],
    y=onoff_df["Temperature"],
    mode='lines',
    name='ON-OFF'
))

fig.add_trace(go.Scatter(
    x=pid_df["Time"],
    y=pid_df["Temperature"],
    mode='lines',
    name='PID'
))

fig.add_trace(go.Scatter(
    x=mpc_df["Time"],
    y=mpc_df["Temperature"],
    mode='lines',
    name='MPC'
))

fig.add_hline(
    y=setpoint,
    line_dash="dash",
    annotation_text="Setpoint"
)

fig.update_layout(
    template="plotly_dark",
    height=500,
    xaxis_title="Time",
    yaxis_title="Temperature (°C)"
)

st.plotly_chart(fig, use_container_width=True)

# -------------------------------------------------
# VALVE POSITION COMPARISON
# -------------------------------------------------

st.markdown("---")
st.subheader("🌀 Cooling Valve Position")

fig2 = make_subplots(rows=1, cols=3,
                     subplot_titles=("ON-OFF", "PID", "MPC"))

fig2.add_trace(
    go.Scatter(
        x=onoff_df["Time"],
        y=onoff_df["Valve"],
        mode='lines'
    ),
    row=1,
    col=1
)

fig2.add_trace(
    go.Scatter(
        x=pid_df["Time"],
        y=pid_df["Valve"],
        mode='lines'
    ),
    row=1,
    col=2
)

fig2.add_trace(
    go.Scatter(
        x=mpc_df["Time"],
        y=mpc_df["Valve"],
        mode='lines'
    ),
    row=1,
    col=3
)

fig2.update_layout(
    template="plotly_dark",
    height=450,
    showlegend=False
)

st.plotly_chart(fig2, use_container_width=True)

# -------------------------------------------------
# CONTROL SYSTEM EXPLANATION
# -------------------------------------------------

st.markdown("---")
st.subheader("📚 Control System Explanation")

st.markdown("""
### 1. ON-OFF Control
- Simplest controller
- Valve fully opens or fully closes
- Causes oscillation
- Used in household thermostats

### 2. PID Control
- Most common industrial controller
- Smooth response
- Reduces overshoot
- Widely used in DCS systems

### 3. MPC Control
- Predictive strategy
- Estimates future behavior
- Used in advanced chemical plants
- Common in refineries and petrochemical plants
""")

# -------------------------------------------------
# PERFORMANCE TABLE
# -------------------------------------------------

st.markdown("---")
st.subheader("📊 Performance Comparison")

performance = pd.DataFrame({
    "Controller": ["ON-OFF", "PID", "MPC"],
    "Final Temp": [
        round(onoff_df["Temperature"].iloc[-1], 2),
        round(pid_df["Temperature"].iloc[-1], 2),
        round(mpc_df["Temperature"].iloc[-1], 2)
    ],
    "Valve Stability": [
        "Low",
        "High",
        "Very High"
    ],
    "Industrial Use": [
        "Basic",
        "Very Common",
        "Advanced"
    ]
})

st.dataframe(performance, use_container_width=True)

# -------------------------------------------------
# FOOTER
# -------------------------------------------------

st.markdown("---")
st.markdown("## ✅ Simulation Complete")
st.markdown("Designed for Chemical Engineering DCS / SCADA Learning")