EVOLV/scripts/patch-flow.js

#!/usr/bin/env node
/**
 * Patch demo-flow.json:
 *   Phase A: Add 4 NH4 measurement nodes + ui-group + ui-chart
 *   Phase B: Add influent composer function node + wire merge collector
 *   Phase C: Fix biomass init on reactor
 *   Phase D: Add RAS pump, flow sensor, 2 injects, filter function + wiring
 */

const fs = require('fs');
const path = require('path');

const flowPath = path.join(__dirname, '..', 'docker', 'demo-flow.json');
const flow = JSON.parse(fs.readFileSync(flowPath, 'utf8'));

// Helper: find node by id
const findNode = (id) => flow.find(n => n.id === id);

// ============================================================
// PHASE A: Add 4 NH4 measurement nodes + ui-group + ui-chart
// ============================================================

const nh4Measurements = [
  {
    id: 'demo_meas_nh4_in',
    name: 'NH4-IN (Ammonium Inlet)',
    uuid: 'nh4-in-001',
    assetTagNumber: 'NH4-IN',
    distance: 0,
    distanceDescription: 'reactor inlet',
    y: 280
  },
  {
    id: 'demo_meas_nh4_a',
    name: 'NH4-A (Early Aeration)',
    uuid: 'nh4-a-001',
    assetTagNumber: 'NH4-A',
    distance: 10,
    distanceDescription: 'early aeration zone',
    y: 320
  },
  {
    id: 'demo_meas_nh4_b',
    name: 'NH4-B (Mid-Reactor)',
    uuid: 'nh4-b-001',
    assetTagNumber: 'NH4-B',
    distance: 25,
    distanceDescription: 'mid-reactor',
    y: 360
  },
  {
    id: 'demo_meas_nh4_c',
    name: 'NH4-C (Near Outlet)',
    uuid: 'nh4-c-001',
    assetTagNumber: 'NH4-C',
    distance: 45,
    distanceDescription: 'near outlet',
    y: 400
  }
];

for (const m of nh4Measurements) {
  flow.push({
    id: m.id,
    type: 'measurement',
    z: 'demo_tab_treatment',
    name: m.name,
    scaling: true,
    i_min: 0,
    i_max: 50,
    i_offset: 0,
    o_min: 0,
    o_max: 50,
    smooth_method: 'mean',
    count: 3,
    simulator: true,
    uuid: m.uuid,
    supplier: 'Hach',
    category: 'sensor',
    assetType: 'ammonium',
    model: 'Amtax-sc',
    unit: 'mg/L',
    assetTagNumber: m.assetTagNumber,
    enableLog: false,
    logLevel: 'error',
    positionVsParent: 'atEquipment',
    x: 400,
    y: m.y,
    wires: [
      ['demo_link_meas_dash', 'demo_link_process_out_treatment'],
      ['demo_link_influx_out_treatment'],
      ['demo_reactor']
    ],
    positionIcon: '⊥',
    hasDistance: true,
    distance: m.distance,
    distanceUnit: 'm',
    distanceDescription: m.distanceDescription
  });
}

// NH4 profile ui-group
flow.push({
  id: 'demo_ui_grp_nh4_profile',
  type: 'ui-group',
  name: 'NH4 Profile Along Reactor',
  page: 'demo_ui_page_treatment',
  width: '6',
  height: '1',
  order: 6,
  showTitle: true,
  className: ''
});

// NH4 profile chart
flow.push({
  id: 'demo_chart_nh4_profile',
  type: 'ui-chart',
  z: 'demo_tab_dashboard',
  group: 'demo_ui_grp_nh4_profile',
  name: 'NH4 Profile',
  label: 'NH4 Along Reactor (mg/L)',
  order: 1,
  width: '6',
  height: '5',
  chartType: 'line',
  category: 'topic',
  categoryType: 'msg',
  xAxisType: 'time',
  yAxisLabel: 'mg/L',
  removeOlder: '10',
  removeOlderUnit: '60',
  action: 'append',
  pointShape: 'false',
  pointRadius: 0,
  interpolation: 'linear',
  x: 510,
  y: 1060,
  wires: [],
  showLegend: true,
  xAxisProperty: '',
  xAxisPropertyType: 'timestamp',
  yAxisProperty: 'payload',
  yAxisPropertyType: 'msg',
  colors: [
    '#0094ce',
    '#FF7F0E',
    '#2CA02C',
    '#D62728',
    '#A347E1',
    '#D62728',
    '#FF9896',
    '#9467BD',
    '#C5B0D5'
  ],
  textColor: ['#aaaaaa'],
  textColorDefault: false,
  gridColor: ['#333333'],
  gridColorDefault: false,
  className: ''
});

// Link out + link in for NH4 profile chart
flow.push({
  id: 'demo_link_nh4_profile_dash',
  type: 'link out',
  z: 'demo_tab_treatment',
  name: '→ NH4 Profile Dashboard',
  mode: 'link',
  links: ['demo_link_nh4_profile_dash_in'],
  x: 620,
  y: 340
});

flow.push({
  id: 'demo_link_nh4_profile_dash_in',
  type: 'link in',
  z: 'demo_tab_dashboard',
  name: '← NH4 Profile',
  links: ['demo_link_nh4_profile_dash'],
  x: 75,
  y: 1060,
  wires: [['demo_fn_nh4_profile_parse']]
});

// Parse function for NH4 profile chart
flow.push({
  id: 'demo_fn_nh4_profile_parse',
  type: 'function',
  z: 'demo_tab_dashboard',
  name: 'Parse NH4 Profile',
  func: `const p = msg.payload || {};
const topic = msg.topic || '';
const now = Date.now();
const val = Number(p.mAbs);
if (!Number.isFinite(val)) return null;

let label = topic;
if (topic.includes('NH4-IN')) label = 'NH4-IN (0m)';
else if (topic.includes('NH4-A')) label = 'NH4-A (10m)';
else if (topic.includes('NH4-B')) label = 'NH4-B (25m)';
else if (topic.includes('NH4-001')) label = 'NH4-001 (35m)';
else if (topic.includes('NH4-C')) label = 'NH4-C (45m)';

return { topic: label, payload: Math.round(val * 100) / 100, timestamp: now };`,
  outputs: 1,
  x: 280,
  y: 1060,
  wires: [['demo_chart_nh4_profile']]
});

// Wire existing NH4-001 and new NH4 measurements to the profile link out
const existingNh4 = findNode('demo_meas_nh4');
if (existingNh4) {
  if (!existingNh4.wires[0].includes('demo_link_nh4_profile_dash')) {
    existingNh4.wires[0].push('demo_link_nh4_profile_dash');
  }
}
for (const m of nh4Measurements) {
  const node = findNode(m.id);
  if (node && !node.wires[0].includes('demo_link_nh4_profile_dash')) {
    node.wires[0].push('demo_link_nh4_profile_dash');
  }
}

console.log('Phase A: Added 4 NH4 measurements + ui-group + chart + wiring');

// ============================================================
// PHASE B: Add influent composer + wire merge collector
// ============================================================

flow.push({
  id: 'demo_fn_influent_compose',
  type: 'function',
  z: 'demo_tab_treatment',
  name: 'Influent Composer',
  func: `// Convert merge collector output to Fluent messages for reactor
// ASM3: [S_O, S_I, S_S, S_NH, S_N2, S_NO, S_HCO, X_I, X_S, X_H, X_STO, X_A, X_TS]
const p = msg.payload || {};
const MUNICIPAL   = [0.5, 30, 200, 40, 0, 0, 5, 25, 150, 30, 0, 0, 200];
const INDUSTRIAL  = [0.5, 40, 300, 25, 0, 0, 4, 30, 100, 20, 0, 0, 150];
const RESIDENTIAL = [0.5, 25, 180, 45, 0, 0, 5, 20, 130, 25, 0, 0, 175];

const Fw = (p.west?.netFlow || 0) * 24;   // m3/h -> m3/d
const Fn = (p.north?.netFlow || 0) * 24;
const Fs = (p.south?.netFlow || 0) * 24;

const msgs = [];
if (Fw > 0) msgs.push({ topic: 'Fluent', payload: { inlet: 0, F: Fw, C: MUNICIPAL }});
if (Fn > 0) msgs.push({ topic: 'Fluent', payload: { inlet: 1, F: Fn, C: INDUSTRIAL }});
if (Fs > 0) msgs.push({ topic: 'Fluent', payload: { inlet: 2, F: Fs, C: RESIDENTIAL }});
return [msgs];`,
  outputs: 1,
  x: 480,
  y: 1040,
  wires: [['demo_reactor']]
});

// Wire merge collector → influent composer (add to existing wires)
const mergeCollect = findNode('demo_fn_merge_collect');
if (mergeCollect) {
  if (!mergeCollect.wires[0].includes('demo_fn_influent_compose')) {
    mergeCollect.wires[0].push('demo_fn_influent_compose');
  }
  console.log('Phase B: Wired merge collector → influent composer → reactor');
} else {
  console.error('Phase B: ERROR — demo_fn_merge_collect not found!');
}

// ============================================================
// PHASE C: Fix biomass initialization
// ============================================================

const reactor = findNode('demo_reactor');
if (reactor) {
  reactor.X_A_init = 300;
  reactor.X_H_init = 1500;
  reactor.X_TS_init = 2500;
  reactor.S_HCO_init = 8;
  console.log('Phase C: Updated reactor biomass init values');
} else {
  console.error('Phase C: ERROR — demo_reactor not found!');
}

// ============================================================
// PHASE D: Return Activated Sludge
// ============================================================

// D1: RAS pump
flow.push({
  id: 'demo_pump_ras',
  type: 'rotatingMachine',
  z: 'demo_tab_treatment',
  name: 'RAS Pump',
  speed: '1',
  startup: '5',
  warmup: '3',
  shutdown: '4',
  cooldown: '2',
  movementMode: 'dynspeed',
  machineCurve: '',
  uuid: 'pump-ras-001',
  supplier: 'hidrostal',
  category: 'machine',
  assetType: 'pump-centrifugal',
  model: 'hidrostal-RAS',
  unit: 'm3/h',
  enableLog: true,
  logLevel: 'info',
  positionVsParent: 'downstream',
  positionIcon: '←',
  hasDistance: false,
  distance: 0,
  distanceUnit: 'm',
  distanceDescription: '',
  x: 1000,
  y: 380,
  wires: [
    ['demo_link_process_out_treatment'],
    ['demo_link_influx_out_treatment'],
    ['demo_settler']
  ],
  curveFlowUnit: 'l/s',
  curvePressureUnit: 'mbar',
  curvePowerUnit: 'kW'
});

// D2: RAS flow sensor
flow.push({
  id: 'demo_meas_ft_ras',
  type: 'measurement',
  z: 'demo_tab_treatment',
  name: 'FT-RAS (RAS Flow)',
  scaling: true,
  i_min: 20,
  i_max: 80,
  i_offset: 0,
  o_min: 20,
  o_max: 80,
  smooth_method: 'mean',
  count: 3,
  simulator: true,
  uuid: 'ft-ras-001',
  supplier: 'Endress+Hauser',
  category: 'sensor',
  assetType: 'flow',
  model: 'Promag-W400',
  unit: 'm3/h',
  assetTagNumber: 'FT-RAS',
  enableLog: false,
  logLevel: 'error',
  positionVsParent: 'atEquipment',
  positionIcon: '⊥',
  hasDistance: false,
  distance: 0,
  distanceUnit: 'm',
  distanceDescription: '',
  x: 1200,
  y: 380,
  wires: [
    ['demo_link_process_out_treatment'],
    ['demo_link_influx_out_treatment'],
    ['demo_pump_ras']
  ]
});

// D3: Inject to set pump mode
flow.push({
  id: 'demo_inj_ras_mode',
  type: 'inject',
  z: 'demo_tab_treatment',
  name: 'RAS → virtualControl',
  props: [
    { p: 'topic', vt: 'str' },
    { p: 'payload', vt: 'str' }
  ],
  topic: 'setMode',
  payload: 'virtualControl',
  payloadType: 'str',
  once: true,
  onceDelay: '3',
  x: 1000,
  y: 440,
  wires: [['demo_pump_ras']],
  repeatType: 'none',
  crontab: '',
  repeat: ''
});

// D3: Inject to set pump speed
flow.push({
  id: 'demo_inj_ras_speed',
  type: 'inject',
  z: 'demo_tab_treatment',
  name: 'RAS speed → 50%',
  props: [
    { p: 'topic', vt: 'str' },
    { p: 'payload', vt: 'json' }
  ],
  topic: 'execMovement',
  payload: '{"source":"auto","action":"setpoint","setpoint":50}',
  payloadType: 'json',
  once: true,
  onceDelay: '4',
  x: 1000,
  y: 480,
  wires: [['demo_pump_ras']],
  repeatType: 'none',
  crontab: '',
  repeat: ''
});

// D4: RAS filter function
flow.push({
  id: 'demo_fn_ras_filter',
  type: 'function',
  z: 'demo_tab_treatment',
  name: 'RAS Filter',
  func: `// Only pass RAS (inlet 2) from settler to reactor as inlet 3
if (msg.topic === 'Fluent' && msg.payload && msg.payload.inlet === 2) {
  msg.payload.inlet = 3;  // reactor inlet 3 = RAS
  return msg;
}
return null;`,
  outputs: 1,
  x: 1000,
  y: 320,
  wires: [['demo_reactor']]
});

// D5: Wire settler Port 0 → RAS filter
const settler = findNode('demo_settler');
if (settler) {
  if (!settler.wires[0].includes('demo_fn_ras_filter')) {
    settler.wires[0].push('demo_fn_ras_filter');
  }
  console.log('Phase D: Wired settler → RAS filter → reactor');
} else {
  console.error('Phase D: ERROR — demo_settler not found!');
}

// D5: Update reactor n_inlets: 3 → 4
if (reactor) {
  reactor.n_inlets = 4;
  console.log('Phase D: Updated reactor n_inlets to 4');
}

console.log('Phase D: Added RAS pump, flow sensor, 2 injects, filter function');

// ============================================================
// WRITE OUTPUT
// ============================================================

fs.writeFileSync(flowPath, JSON.stringify(flow, null, 2) + '\n', 'utf8');
console.log(`\nDone. Wrote ${flow.length} nodes to ${flowPath}`);