EVOLV/test/mgc-overactive-demand-serialization.integration.test.js

// Regression: MGC must serialize concurrent handleInput calls.
//
// Live observation (2026-05-09): PS sends a fresh demand% every 1 s as
// basin level drifts. Each MGC.handleInput unconditionally calls
// abortActiveMovements — so an in-flight pump ramp gets killed, the
// pump's setpoint is replaced, the new ramp gets killed by the next
// tick, and the loop never settles. Real symptom: 120
// "Aborting active movements ..." log lines per 2 min while a single
// pump randomly leads (138 m³/h) and the others are clamped at minFlow
// (60 m³/h, "near_curve_edge").
//
// Proper design (mirrors rotatingMachine state.delayedMove): when a
// handleInput is already in-flight (pumps still moving), save the new
// demand to a delayed slot and return. When the in-flight dispatch
// finishes, pick up the latest delayed demand. Latest-wins —
// intermediate values are stomped because they were obsolete by the
// time the pumps were ready for them.
//
// Fail mode this catches: any future change that re-introduces
// concurrent handleInput entries (or removes the gate) will explode the
// abort count and leave pumps unbalanced.

const test = require('node:test');
const assert = require('node:assert/strict');
const { buildPlant, injectPumpPressure } = require('./lib/wiring');

test('MGC serializes overactive demand — one dispatch in flight at a time, latest queued for pickup', async () => {
  const plant = buildPlant({ initialBasinLevel: 2.6 });
  const { mgc, pumps, restore } = plant;
  try {
    // Realistic ramp time so the in-flight window is wide enough that
    // multiple PS calls land during it.
    for (const p of pumps) {
      p.state.config.time = { starting: 1, warmingup: 1, stopping: 1, coolingdown: 1 };
      injectPumpPressure(p, 19620, 117720);
    }
    // Bring pumps to operational once so the test focuses on
    // STEADY-STATE thrash (not startup).
    for (const p of pumps) await p.handleInput('parent', 'execsequence', 'startup');

    // Count how many times MGC actually issues an abort. Wrap the
    // existing method so the contract is enforced regardless of
    // implementation details.
    let abortCount = 0;
    const originalAbort = mgc.abortActiveMovements.bind(mgc);
    mgc.abortActiveMovements = async (reason) => {
      abortCount += 1;
      return originalAbort(reason);
    };

    // Simulate PS jitter: 30 demand calls fired back-to-back without
    // awaiting (mirrors PS._applyMachineGroupLevelControl firing into
    // an MGC whose previous handleInput is still settling pumps).
    // Tiny percControl drift around 14 % matches what we observed live.
    const calls = [];
    const baseDemand = 14;
    for (let i = 0; i < 30; i++) {
      const d = baseDemand + (i % 5) * 0.05;
      // Fire-and-forget — the gate must absorb the burst.
      calls.push(mgc.handleInput('parent', d).catch(() => {}));
    }
    await Promise.all(calls);
    // Let any deferred pickup settle.
    await new Promise((r) => setImmediate(r));
    await new Promise((r) => setImmediate(r));

    // Contract: with a serialization gate, concurrent burst yields at
    // most TWO real dispatches (the first that wins entry, plus one
    // queued pickup carrying the latest value). Without the gate, every
    // call aborts → abortCount equals call count.
    //
    // We assert ≤ 5 to allow for legitimate sequential dispatch that
    // span a few ticks but block the runaway-thrash mode.
    assert.ok(abortCount <= 5,
      `MGC issued ${abortCount} aborts for 30 concurrent demand calls — gate not serializing dispatches (live system showed 1 abort/sec / 120 per 2 min with this exact bug).`);

    // Whatever combination the optimizer picks, all selected pumps
    // must reach a non-floor ctrl. Pump_b stuck at the curve floor was
    // the live failure — the gate fixes it because the ramp completes
    // before the next demand starts.
    const finalCtrls = pumps.map((p) => Number(p.state.getCurrentPosition?.()) || 0);
    const activePumps = finalCtrls.filter((c) => c > 0);
    if (activePumps.length >= 2) {
      const min = Math.min(...activePumps);
      const max = Math.max(...activePumps);
      assert.ok(max / Math.max(min, 1) < 3,
        `active pump ctrls=${activePumps.map((c) => c.toFixed(1))} — disparity > 3× indicates one pump clamped at curve floor (the live "138 vs 60" symptom).`);
    }
  } finally {
    restore();
  }
});

test('MGC serialization preserves latest-wins semantic — intermediate values stomped, last value applied', async () => {
  const plant = buildPlant({ initialBasinLevel: 2.6 });
  const { mgc, pumps, restore } = plant;
  try {
    for (const p of pumps) {
      p.state.config.time = { starting: 1, warmingup: 1, stopping: 1, coolingdown: 1 };
      injectPumpPressure(p, 19620, 117720);
    }
    for (const p of pumps) await p.handleInput('parent', 'execsequence', 'startup');

    // Fire 10 demands quickly: 25, 50, 25, 50, ..., 100. Final must be 100.
    const sequence = [25, 50, 25, 50, 25, 50, 25, 50, 25, 100];
    const calls = sequence.map((d) => mgc.handleInput('parent', d).catch(() => {}));
    await Promise.all(calls);
    // Allow one extra event-loop turn for the deferred pickup.
    await new Promise((r) => setImmediate(r));
    await new Promise((r) => setImmediate(r));

    // After settling, the LATEST demand (100 %) wins — pumps should be
    // at high ctrl, not stuck on the first burst-leader value.
    const finalCtrls = pumps.map((p) => Number(p.state.getCurrentPosition?.()) || 0);
    const maxCtrl = Math.max(...finalCtrls);
    assert.ok(maxCtrl > 70,
      `latest demand was 100 % but max pump ctrl=${maxCtrl.toFixed(1)} — gate is dropping the queued value instead of picking it up.`);
  } finally {
    restore();
  }
});