Duplex pump controller

Implementation

Implemented OFF, STARTING, RUNNING and FAULT states with scan-ordered interlocks.

Executed 23 regression tests, a 14,336-case one-scan interlock sweep, and a 46-second fault trace.

Executed synthetic/theoretical validation with a selected operating envelope, adverse conditions, and reproducible acceptance evidence.

Inputs and assumptions

• Three ordered level switches; reference timers of 3 s start timeout, 1 s feedback loss, and 10 s minimum run.
• Quiet-input manual reset is required at initial boot and after control-power loss.

Results

Report figures (2)

Open the full report ↗

Verification

23 tests and 10 independent trace checkpoints passed. Additional virtual validation: 36 checks matched their expected outcomes. Adverse design conditions remain in the results.

python run.py

Project files

The ZIP contains the source, inputs, results, and instructions. These files are also available individually.

• Controller sourcecontroller.py · 7 KB
• Regression teststest_controller.py · 8 KB
• I/O listio_list.csv · 1 KB
• Cause-and-effect tablecause_and_effect.csv · 1 KB
• Simulation traceresults/scenario_trace.csv · 2 KB
• Expected outputsresults/expected_outputs.csv · 1 KB
• Hardware acceptance procedurehardware_acceptance.md · 2 KB
• Verification recordverification.json · 3 KB
• Virtual validation reportvirtual-validation.html · 13 KB
• Completion evidence and source hashescompletion.json · 12 KB
• Reproducible virtual validationvirtual_commissioning.py · 12 KB
• Executed acceptance matrixresults/virtual-acceptance.csv · 6 KB
• Selected plant envelope and restoration policyselected-operating-envelope.json · 1 KB
• Synthetic reservoir traces: 200 L capacity and 180 L high-level referencefigures/virtual-reservoir.svg · 49 KB
• Reservoir case summaryresults/virtual-reservoir-summary.csv · 1 KB
• All coupled reservoir and command tracesresults/virtual-reservoir-traces.csv · 3.9 MB
• Scan timing sweepresults/virtual-scan-timing.csv · 1 KB

Run locally

Python 3.10+ / NumPy and Matplotlib for report plots; the controller and tests use the Python standard library.

Extract the ZIP and open a terminal in the duplex-pump-controller folder. The README includes setup and usage details.

python -m pip install -r requirements.txt
python run.py
python -m unittest -v

Limits

• An executable supervisory model, not deployed PLC firmware or commissioned pump hardware.
• External availability inputs stand in for motor protection, emergency circuits, and mechanical safeguards.
• Timers are evaluated on scans. A physical implementation must bound scan time and feedback latency.
• The input sweep is exhaustive for one scan at seven representative states, not for all continuous-time histories.
• Persistent fault/lead memory is modeled in a live process; a deployed controller needs specified nonvolatile storage behavior.