Create app.py

app.py

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+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")