Calejo Control Adapter

Multi-protocol integration adapter for municipal wastewater pump stations with comprehensive safety and security framework

Overview

The Calejo Control Adapter translates optimized pump control plans from Calejo Optimize into real-time control signals for municipal wastewater pump stations. It supports diverse SCADA systems with minimal configuration through automatic discovery and multiple protocol support.

Implementation Status

✅ Phase 1: Core Infrastructure

• Database connection pooling with FlexibleDatabaseClient
• Auto-discovery of pump stations and pumps
• Safety framework with limit enforcement
• Emergency stop management
• Optimization plan management

✅ Phase 2: Multi-Protocol Servers

• OPC UA server implementation
• Modbus TCP server implementation
• REST API server implementation
• Database watchdog for failsafe operation
• Alert management system

✅ Phase 3: Setpoint Management

• Setpoint Manager for real-time control with three calculator types:
  • DIRECT_SPEED: Direct speed control
  • LEVEL_CONTROLLED: Level-based control with feedback
  • POWER_CONTROLLED: Power-based control with feedback
• Integration with all safety components
• Unified main application
• 15 comprehensive unit tests for SetpointManager

✅ Phase 4: Security Layer

• JWT-based authentication with bcrypt password hashing
• Role-based access control (RBAC) with four user roles
• TLS/SSL encryption with certificate management
• Compliance audit logging for IEC 62443, ISO 27001, and NIS2
• 56 comprehensive security tests (24 auth/authz, 17 TLS, 15 audit)

✅ Phase 5: Protocol Server Enhancements

• Enhanced OPC UA server with node caching and performance monitoring
• Optimized Modbus TCP server with connection pooling and industrial features
• Enhanced REST API with OpenAPI documentation, response caching, and compression
• Protocol-specific security enhancements and performance optimizations
• 31 comprehensive tests for protocol enhancements (23 unit + 8 integration)

⏳ Phase 6: Integration and Testing (Pending)

• End-to-end testing
• Validation with real SCADA systems

⏳ Phase 7: Production Hardening (Pending)

• Performance optimization
• Monitoring and alerting

Current Status: All 220 tests passing (100% success rate)

Recent Updates:

• SetpointManager fully integrated with main application
• Added start/stop methods for SetpointManager
• Fixed configuration settings and database pool parameters
• Updated protocol server initializations
• Verified main application starts and stops gracefully
• Fixed main application integration with enhanced protocol servers
• All 220 tests passing (100% success rate)

Key Features

• Multi-Protocol Support: OPC UA, Modbus TCP, and REST API simultaneously
• Auto-Discovery: Automatically discovers pump stations and pumps from database
• Safety Framework: Multi-layer limits, watchdogs, emergency stop, failsafe mechanisms
• Security: Authentication, authorization, encryption, audit logging
• Compliance: IEC 62443, NIS2 Directive, ISO 27001
• High Availability: Caching, failover, health monitoring

Architecture

┌─────────────────────────────────────────────────────────┐
│  Calejo Optimize Container (Existing)                   │
│  - Optimization Engine                                  │
│  - PostgreSQL Database (pump plans)                     │
└─────────────────────────────────────────────────────────┘
                          ↓
┌─────────────────────────────────────────────────────────┐
│  Calejo Control Adapter (IMPLEMENTED)                   │
│                                                          │
│  ┌────────────────────────────────────────────────┐    │
│  │  Core Components:                               │    │
│  │  1. Auto-Discovery Module ✅                    │    │
│  │  2. Safety Framework ✅                         │    │
│  │  3. Emergency Stop Manager ✅                   │    │
│  │  4. Optimization Plan Manager ✅                │    │
│  │  5. Setpoint Manager ✅                         │    │
│  │  6. Database Watchdog ✅                        │    │
│  │  7. Alert Manager ✅                            │    │
│  │  8. Multi-Protocol Server ✅                    │    │
│  │     - OPC UA Server                             │    │
│  │     - Modbus TCP Server                         │    │
│  │     - REST API                                  │    │
│  └────────────────────────────────────────────────┘    │
└─────────────────────────────────────────────────────────┘
                          ↓
                  (Multiple Protocols)
                          ↓
        ┌─────────────────┼─────────────────┐
        ↓                 ↓                  ↓
   Siemens WinCC    Schneider EcoStruxure  Rockwell FactoryTalk

Project Structure

calejo-control-adapter/
├── src/
│   ├── core/
│   │   ├── auto_discovery.py     # Auto-discovery module
│   │   ├── safety.py             # Safety framework
│   │   ├── emergency_stop.py     # Emergency stop manager
│   │   ├── optimization_manager.py # Optimization plan manager
│   │   └── setpoint_manager.py   # Setpoint manager
│   ├── protocols/
│   │   ├── opcua_server.py       # OPC UA server
│   │   ├── modbus_server.py      # Modbus TCP server
│   │   └── rest_api.py           # REST API server
│   ├── database/
│   │   ├── flexible_client.py    # Flexible database client
│   │   └── models.py             # Data models
│   ├── monitoring/
│   │   ├── watchdog.py           # Database watchdog
│   │   └── alerts.py             # Alert manager
│   └── main.py                   # Main application
├── tests/
├── config/
│   ├── settings.py               # Application settings
│   └── docker-compose.yml        # Docker configuration
├── docs/
│   ├── ARCHITECTURE.md           # Comprehensive system architecture
│   ├── SAFETY_FRAMEWORK.md       # Multi-layer safety architecture
│   ├── SECURITY_COMPLIANCE.md    # Security controls and compliance
│   ├── PROTOCOL_INTEGRATION.md   # OPC UA, Modbus, REST API integration
│   ├── INSTALLATION_CONFIGURATION.md # Installation and configuration guide
│   ├── specification.txt         # Full implementation specification
│   ├── optimization_plan_management.md  # Optimization system documentation
│   └── alert_system_setup.md     # Alert system configuration guide
├── requirements.txt              # Python dependencies
├── Dockerfile                    # Docker container definition
└── README.md                     # This file

🚀 Simplified Deployment

One-Click Setup

Run one script, then configure everything through the web dashboard.

# Run the setup script (auto-detects configuration from deploy/ directory)
./setup-server.sh

# For local development
./setup-server.sh -h localhost

# Preview what will be done
./setup-server.sh --dry-run

The script automatically reads from existing deployment configuration files and handles everything:

• Server provisioning and dependency installation
• Application deployment and service startup
• SSL certificate generation
• Health validation

Web-Based Configuration

After setup, access the dashboard at http://your-server:8080/dashboard to configure:

• SCADA protocols (OPC UA, Modbus TCP)
• Pump stations and hardware
• Safety limits and emergency procedures
• User accounts and permissions
• Monitoring and alerts

No manual configuration files or SSH access needed!

---

Default Credentials

After deployment:

• Grafana Dashboard: admin / admin (http://localhost:3000)
• Prometheus Metrics: No authentication required (http://localhost:9091)
• PostgreSQL Database: calejo / password (localhost:5432)
• Main Dashboard: http://localhost:8080/dashboard

Security Note: Change default passwords after first login!

---

Traditional Installation (Alternative)

If you prefer manual setup:

Prerequisites

• Python 3.11+
• PostgreSQL 14+
• Docker (optional)

Manual Installation

1. Clone the repository

   git clone http://95.111.206.201:3000/calejocontrol/CalejoControl.git
   cd calejo-control-adapter
   

2. Install dependencies

   pip install -r requirements.txt
   

3. Set up environment variables

   cp config/.env.example config/.env
   # Edit config/.env with your database and security settings
   

4. Run the application

   python -m src.main
   

Docker Deployment

# Build the container
docker build -t calejo-control-adapter .

# Run the container
docker run -p 8080:8080 -p 4840:4840 -p 502:502 calejo-control-adapter

Configuration

Key configuration options:

• DATABASE_URL: PostgreSQL connection string
• OPC_UA_ENDPOINT: OPC UA server endpoint (default: opc.tcp://0.0.0.0:4840)
• MODBUS_PORT: Modbus TCP port (default: 502)
• REST_API_PORT: REST API port (default: 8080)
• SAFETY_TIMEOUT_SECONDS: Database watchdog timeout (default: 1200)

Documentation

Comprehensive documentation is available in the docs/ directory:

• System Architecture: Complete system architecture and component interactions
• Safety Framework: Multi-layer safety architecture and emergency procedures
• Security & Compliance: Security controls and regulatory compliance framework
• Protocol Integration: OPC UA, Modbus TCP, and REST API integration guide
• Installation & Configuration: Step-by-step installation and configuration guide
• Alert System Setup: Alert system configuration (email, SMS, webhook)
• Optimization Plan Management: Optimization plan processing and management

Alert System Configuration

For detailed alert system setup (email, SMS, webhook integration), see: Alert System Setup Guide

Safety Framework

The adapter implements a comprehensive three-layer safety architecture:

1. Layer 1: Physical Hard Limits (PLC/VFD) - 15-55 Hz
2. Layer 2: Station Safety Limits (Database) - 20-50 Hz (enforced by adapter)
3. Layer 3: Optimization Constraints (Calejo Optimize) - 25-45 Hz

Safety Features

• Hard Operational Limits: Speed, level, power, and flow limits
• Rate of Change Limits: Prevent sudden speed changes
• Database Watchdog: Reverts to safe defaults if updates stop
• Emergency Stop: Manual override capability
• Failsafe Mode: Automatic fallback to default setpoints

Security & Compliance

• Authentication: JWT tokens and certificate-based authentication
• Authorization: Role-based access control (RBAC)
• Encryption: TLS/SSL for all communications
• Audit Logging: Immutable audit trail for compliance
• Standards: IEC 62443, ISO 27001, NIS2 Directive

Development

Running Tests

pytest tests/

Code Quality

flake8 src/ tests/          # Linting
mypy src/                   # Type checking
black src/ tests/           # Code formatting

Contributing

1. Fork the repository
2. Create a feature branch
3. Make your changes
4. Add tests
5. Submit a pull request

License

This project is licensed under the MIT License - see the LICENSE file for details.

Support

For support and documentation, refer to the specification in docs/specification.txt or contact the development team.