Industrial PLC Simulator

A professional-grade HTTP-based PLC simulator with 295+ realistic industrial tags for testing industrial automation applications, SCADA systems, and PLC monitoring tools.

• HTTP REST API for easy integration
• 295+ Realistic Industrial Tags across 12 process areas
• Industry-standard naming conventions (ISA-88, Allen-Bradley)
• Complete data type support (SINT, INT, DINT, REAL, BOOL, SSTRING, STRING)
• Dynamic process simulation with realistic behaviors
• Cross-platform - runs on Windows, Linux, macOS
• Zero Dependencies - uses only Python standard library
• CORS Support for web applications

git clone https://github.com/Digital-Energy/industrial-plc-simulator.git
cd industrial-plc-simulator
python industrial_plc_simulator.py

The server will start on http://localhost:8001

# Start the simulator
python industrial_plc_simulator.py

# Get all available tags (295+)
curl http://localhost:8001/tags

# Read reactor system tags
curl "http://localhost:8001/read?tags=R0101_TIC_2101_PV,R0101_PIC_2103_PV,R0101_LIC_2104_PV"

# Get tags organized by plant areas
curl http://localhost:8001/areas

# Monitor alarms
curl http://localhost:8001/alarms

Total: 295+ Industrial Tags

Returns all available PLC tags with their data types and current values.

Response:

{
  "tags": [
    {
      "name": "R0101_TIC_2101_PV",
      "type": "REAL",
      "value": 348.5
    },
    {
      "name": "P0201_M_SPEED_ACTUAL",
      "type": "REAL", 
      "value": 1750.0
    }
  ],
  "total_tags": 295,
  "status": "Success"
}

Read current values for specified tags.

Example:

curl "http://localhost:8001/read?tags=R0101_TIC_2101_PV,P0201_M_SPEED_ACTUAL,CV0301_POSITION_FB"

Response:

{
  "values": {
    "R0101_TIC_2101_PV": {
      "value": 348.5,
      "type": "REAL",
      "quality": "GOOD",
      "timestamp": "2025-07-30T21:30:00.000000"
    }
  },
  "status": "Success"
}

Returns tags organized by plant areas.

Returns current alarm status and alarm summary.

Write tag values (JSON body):

{
  "R0101_TIC_2101_SP": 355.0,
  "CV0301_POSITION_CMD": 60.0
}

• Dynamic Tag Values: Real-time simulation with process dynamics
• Temperature Cycling: Realistic first-order temperature responses
• Flow Calculations: Based on pump speed and valve positions
• Batch Progress: Time-based production simulation
• Equipment Health: Vibration and temperature monitoring
• Process Interactions: Tags that influence each other realistically

• Primary Reactor R-101 with full instrumentation
• Temperature, Pressure, Level, Flow control loops
• Agitator systems with VFD control
• pH and Conductivity monitoring
• Safety systems (PSV, Rupture Discs, E-Stop)

• Centrifugal Feed Pump P-201 with full diagnostics
• Motor parameters (Current, Voltage, Power, Torque)
• VFD status and fault codes
• Vibration monitoring (X, Y, Z axes)
• Bearing temperature monitoring
• Cavitation detection

• Control Valves with position feedback
• Emergency Shutdown Valves (ESD)
• Motor Operated Valves (MOV)
• Pneumatic actuator pressure
• Travel limit switches

• Safety Instrumented System (SIS)
• Gas Detection (H2S, LEL, O2, CO)
• Fire Detection and Suppression
• Emergency trip systems

• Batch control with ISA-88 states
• Recipe management with versions
• Production rates and totals
• Quality control parameters
• Overall Equipment Effectiveness (OEE)

import requests

# Get all tags
response = requests.get('http://localhost:8001/tags')
tags = response.json()['tags']

# Read specific values
response = requests.get('http://localhost:8001/read?tags=R0101_TIC_2101_PV,P0201_M_SPEED_ACTUAL')
values = response.json()['values']
print(f"Reactor Temperature: {values['R0101_TIC_2101_PV']['value']}°C")

// Fetch all tags
fetch('http://localhost:8001/tags')
  .then(response => response.json())
  .then(data => console.log('Available tags:', data.total_tags));

// Read tag values
fetch('http://localhost:8001/read?tags=R0101_TIC_2101_PV,P0201_M_SPEED_ACTUAL')
  .then(response => response.json())
  .then(data => console.log('Tag values:', data.values));

• Development & Testing - Test PLC applications without hardware
• CI/CD Pipelines - Automated testing of industrial software
• Training & Education - Learn PLC communication protocols
• Rapid Prototyping - Quick development of HMI/SCADA applications
• Demo Environments - Showcase industrial automation solutions
• Integration Testing - Validate communication with PLC monitoring tools

• Python 3.6+
• No additional dependencies - uses only Python standard library

Designed to work seamlessly with:

• SCADA Systems - Industrial HMI/SCADA applications
• PLC Monitoring Tools - SignalTap, FactoryTalk, etc.
• Allen-Bradley Communication Libraries - pylogix and other bindings
• OPC Clients - through HTTP REST interface
• Custom Automation Tools - via simple HTTP API
• Web Applications - with CORS support

MIT License - See LICENSE file for details.

1. Fork the repository
2. Create a feature branch (git checkout -b feature/amazing-feature)
3. Commit your changes (git commit -m 'Add some amazing feature')
4. Push to the branch (git push origin feature/amazing-feature)
5. Open a Pull Request

• Issues: Create an issue on GitHub
• Questions: Check the documentation for integration examples
• Documentation: See code comments for implementation details

⚠️ Note: This is a simulation tool for development and testing purposes. Do not use in production environments with real industrial equipment.

Digital Energy Services | www.digitalenergyservices.ca | Industrial Automation Testing Platform