EVOLV/test/end-to-end-pumpingstation.test.js

// End-to-end test: PS + MGC + 3 pumps wired exactly like the
// pumpingstation-complete-example demo, driven by a controllable clock.
//
// Verifies:
//   1. Basin starts low (below stopLevel) — pumps OFF.
//   2. Basin fills to startLevel — first pump engages.
//   3. Basin drains through the dead band [stopLevel, startLevel] —
//      pump stays engaged at minimum flow.
//   4. Basin reaches stopLevel — pump disengages, basin refills.
//   5. Storm inflow → all 3 pumps engage at high flow.

const test = require('node:test');
const { buildPlant, injectPumpPressure } = require('./lib/wiring');
const { attachRecorder, snapshotFull, snapshotMachineState } = require('./lib/recorder');

const TICK_MS = 1000;
const STATIC_HEAD_M  = 12;
const RHO_G = 9810;
const DYN_HEAD_M_AT_FULL_FLOW = 12;
const TOTAL_FLOW_MAX_M3H = 300;
const OUTFLOW_LEVEL_M = 0.3;

function physics({ basinLevelM, totalPumpFlow_m3h }) {
  const headM = Math.max(0, basinLevelM - OUTFLOW_LEVEL_M);
  const upstreamPa = RHO_G * headM;
  const ratio = Math.min(1, totalPumpFlow_m3h / TOTAL_FLOW_MAX_M3H);
  const downstreamPa = RHO_G * (STATIC_HEAD_M + ratio * ratio * DYN_HEAD_M_AT_FULL_FLOW);
  return { upstreamPa, downstreamPa };
}

function totalPumpFlow_m3h(pumps) {
  let s = 0;
  for (const p of pumps) {
    const f = p.measurements.type('flow').variant('predicted').position('downstream').getCurrentValue('m3/h') || 0;
    s += Number(f);
  }
  return s;
}

async function tick(plant, { qIn_m3s }) {
  const { ps, pumps, advance } = plant;
  const basinLevelM = ps.measurements.type('level').variant('predicted')
    .position('atequipment').getCurrentValue('m') ?? 0;
  const tot = totalPumpFlow_m3h(pumps);
  const { upstreamPa, downstreamPa } = physics({ basinLevelM, totalPumpFlow_m3h: tot });
  for (const p of pumps) injectPumpPressure(p, upstreamPa, downstreamPa);
  ps.setManualInflow(qIn_m3s, Date.now(), 'm3/s');
  advance(TICK_MS);
  ps.tick();
  await new Promise((r) => setImmediate(r));
}

test('PS + MGC + 3 pumps — full hysteresis cycle (5/15 nominal)', async () => {
  // Start at 2.4 m — just below startLevel(2.5) — so we see the rising
  // edge in a few minutes instead of 30. Then observe the full cycle.
  const plant = buildPlant({ initialBasinLevel: 2.4 });
  const rec = attachRecorder(plant);
  const { ps, mgc, pumps, restore } = plant;

  try {
    console.log('\n=========================================================');
    console.log(' POST-WIRING SNAPSHOT');
    console.log('=========================================================');
    const initSnap = snapshotFull(ps, mgc, pumps);
    console.log(JSON.stringify(initSnap, null, 2));
    console.log('\nMGC absoluteTotals (m³/h):',
      `min=${(mgc.absoluteTotals.flow.min*3600).toFixed(0)}, max=${(mgc.absoluteTotals.flow.max*3600).toFixed(0)}`);
    console.log('MGC dynamicTotals (m³/h):',
      `min=${(mgc.dynamicTotals.flow.min*3600).toFixed(0)}, max=${(mgc.dynamicTotals.flow.max*3600).toFixed(0)}`);

    // Phase 1: nominal inflow ≈ 25 m³/h → expect cycle ~5 on / ~15 off.
    const NOMINAL_QIN = 25 / 3600;  // m³/s
    console.log('\n=========================================================');
    console.log(' PHASE 1: nominal inflow 25 m³/h — observe one full cycle.');
    console.log(' Expected: basin rises from 1.5 m to 2.5 m (off, ~?? min), pump kicks on, drains to 2.0 m (on, ~5 min), repeats.');
    console.log('=========================================================');

    const phase1Trace = [];
    let firstEngageTick = null;
    let firstDisengageTick = null;
    let secondEngageTick = null;
    for (let i = 0; i < 1800; i++) {  // 30 min sim
      await tick(plant, { qIn_m3s: NOMINAL_QIN });
      const snap = snapshotFull(ps, mgc, pumps);
      const tickIdx = i + 1;
      phase1Trace.push({ s: tickIdx, ...snap });
      const anyEngaged = pumps.some(p =>
        ['operational', 'starting', 'warmingup', 'accelerating'].includes(p.state.getCurrentState())
      );
      if (anyEngaged && firstEngageTick == null) firstEngageTick = tickIdx;
      if (firstEngageTick != null && firstDisengageTick == null && !anyEngaged) firstDisengageTick = tickIdx;
      if (firstDisengageTick != null && secondEngageTick == null && anyEngaged) secondEngageTick = tickIdx;
      // Stop after we observe a full off→on→off→on cycle so we can measure both phases.
      if (secondEngageTick != null && tickIdx > secondEngageTick + 60) break;
    }
    printCompactTrace(decimateTrace(phase1Trace, 30));

    console.log('\n-- cycle landmarks --');
    console.log(`First pump engage   : tick ${firstEngageTick}  (level=${phase1Trace[firstEngageTick - 1]?.psLevel})`);
    console.log(`First pump disengage: tick ${firstDisengageTick}  (level=${phase1Trace[firstDisengageTick - 1]?.psLevel})`);
    console.log(`Second engage       : tick ${secondEngageTick}  (level=${phase1Trace[secondEngageTick - 1]?.psLevel})`);
    if (firstEngageTick && firstDisengageTick) {
      const onMin = (firstDisengageTick - firstEngageTick) / 60;
      console.log(`On phase duration   : ${onMin.toFixed(1)} min  (target ≈ 5 min)`);
    }
    if (firstDisengageTick && secondEngageTick) {
      const offMin = (secondEngageTick - firstDisengageTick) / 60;
      console.log(`Off phase duration  : ${offMin.toFixed(1)} min  (target ≈ 15 min)`);
    }

    // Phase 2: storm inflow → all 3 pumps should engage.
    console.log('\n=========================================================');
    console.log(' PHASE 2: storm inflow 250 m³/h — expect all 3 pumps engaged.');
    console.log('=========================================================');
    const STORM_QIN = 250 / 3600;
    const phase2Trace = [];
    for (let i = 0; i < 600; i++) {  // 10 min storm
      await tick(plant, { qIn_m3s: STORM_QIN });
      const snap = snapshotFull(ps, mgc, pumps);
      phase2Trace.push({ s: phase1Trace.length + i + 1, ...snap });
    }
    printCompactTrace(decimateTrace(phase2Trace, 30));

    const peak = phase2Trace.reduce((acc, s) => {
      const running = Object.values(s.pumps).filter(p =>
        ['operational', 'accelerating', 'warmingup', 'starting'].includes(p.state)
      ).length;
      return Math.max(acc, running);
    }, 0);
    console.log(`\nPeak concurrent running pumps during storm: ${peak} / 3`);
    const maxLvl = phase2Trace.reduce((acc, s) => Math.max(acc, s.psLevel ?? 0), 0);
    console.log(`Max basin level during storm: ${maxLvl.toFixed(2)} m`);

    // Phase 3: inflow drops back to nominal — expect graceful unwind.
    console.log('\n=========================================================');
    console.log(' PHASE 3: storm subsides → 25 m³/h. Expect graceful unwind.');
    console.log('=========================================================');
    const phase3Trace = [];
    for (let i = 0; i < 900; i++) {
      await tick(plant, { qIn_m3s: NOMINAL_QIN });
      const snap = snapshotFull(ps, mgc, pumps);
      phase3Trace.push({ s: phase1Trace.length + phase2Trace.length + i + 1, ...snap });
      const anyEngaged = pumps.some(p =>
        ['operational', 'starting'].includes(p.state.getCurrentState())
      );
      if (!anyEngaged) break;
    }
    printCompactTrace(decimateTrace(phase3Trace, 30));

    // Diagnostics summary.
    console.log('\n=========================================================');
    console.log(' SUMMARY');
    console.log('=========================================================');
    const ctrlAnomalies = phase1Trace.filter(s =>
      Object.values(s.pumps).some(p =>
        p.state === 'operational' && (p.ctrl_pct === 0 || p.ctrl_pct == null) && p.flow_m3h > 1
      )
    ).length;
    console.log(`Bug 3 leftover (ctrl=0 while operational delivering flow): ${ctrlAnomalies} ticks`);
    const optimalEvents = rec.events.filter(e => e.kind === 'mgc.optimalControl.out' && e.Qd > 0);
    console.log(`MGC optimalControl invocations with Qd>0: ${optimalEvents.length}`);
  } finally {
    restore();
  }
});

// Reduce noise by sampling every Nth tick + always include first/last.
function decimateTrace(rows, step) {
  if (rows.length <= step * 2) return rows;
  const out = [rows[0]];
  for (let i = step; i < rows.length - 1; i += step) out.push(rows[i]);
  out.push(rows[rows.length - 1]);
  return out;
}

function printCompactTrace(rows) {
  if (rows.length === 0) { console.log('(empty)'); return; }
  console.log('   s  level  vol    dir       pct      d_min  d_max   pumpA           pumpB           pumpC');
  console.log('   ─  ─────  ─────  ────────  ───────  ─────  ─────   ───────────────  ───────────────  ───────────────');
  for (const r of rows) {
    const fmtPump = (p) => {
      if (!p) return ''.padEnd(15);
      return `${(p.state ?? '?').slice(0,8).padEnd(8)} c${(p.ctrl_pct ?? 0).toFixed(0).padStart(3)} f${(p.flow_m3h ?? 0).toFixed(0).padStart(3)}`.padEnd(15);
    };
    const a = fmtPump(r.pumps.pump_a);
    const b = fmtPump(r.pumps.pump_b);
    const c = fmtPump(r.pumps.pump_c);
    console.log(
      `${String(r.s).padStart(4)}  ${(r.psLevel ?? 0).toFixed(3)}  ${(r.psVolume ?? 0).toFixed(2).padStart(5)}  ${(r.psDirection ?? '?').padEnd(8)}  ${(r.psPercControl ?? 0).toFixed(2).padStart(7)}  ${(r.mgc?.dynamicMin_m3h ?? 0).toFixed(0).padStart(5)}  ${(r.mgc?.dynamicMax_m3h ?? 0).toFixed(0).padStart(5)}   ${a}  ${b}  ${c}`
    );
  }
}