EVOLV/test/inflow-overcapacity-stability.integration.test.js

// Stability under inflow > station capacity: storm condition where the
// basin overflows continuously. Pumps should run flat-out and the FSM
// must NOT thrash through aborts/parks.
//
// Catches the user's live observation: at 2× capacity inflow, pumps got
// stuck mid-flight while demand was still rising. This test runs with
// realistic state.time (production defaults) so the abort-during-startup
// race window is fully open.

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

const TICK_MS = 1000;
// Sim duration kept short — the chronic thrashing pattern shows up
// within the first minute. Bigger SIM_MINUTES makes the test wall-time
// hostile (each tick awaits async pump moves on real timers).
const SIM_SECONDS = 45;

test('inflow ≫ capacity: pumps reach steady high-ctrl, no parking, no thrashing', async () => {
  // Use shorter-than-default state.time so the test runs in reasonable
  // wall time while still exercising the transient (1 s startup + 2 s
  // warmup). The race conditions we care about are the same — they're
  // about ORDER, not absolute duration.
  // Start at maxLevel so PS percControl is immediately 100 % (the
  // storm condition). Otherwise the basin needs to fill to maxLevel
  // first, which on a 2× capacity inflow takes ~2 minutes — longer
  // than this test's wall time.
  const plant = buildPlant({ initialBasinLevel: 3.5 });
  const { ps, mgc, pumps, advance, restore } = plant;
  try {
    // Pre-start pumps to operational so the test focuses on STEADY-STATE
    // thrashing under chronic over-capacity inflow, not startup race
    // conditions (those have their own test). This also keeps wall time
    // manageable — buildPlant's state.time=0 means transitions are
    // instant once already operational.
    for (const p of pumps) await p.handleInput('parent', 'execsequence', 'startup');

    // Inflow set 2× station capacity (~600 m³/h vs ~270 m³/h capacity).
    const Q_IN = 600 / 3600;

    let parkObservations = 0;
    let abortLogObservations = 0;

    // Drive the loop: every tick, refresh pressures, set inflow,
    // tick PS (which fires _applyMachineGroupLevelControl). The
    // settlePerTickMs wait is REAL wall-clock so movementManager's
    // setInterval timers actually fire between handleInputs — without
    // it the test runs too fast for moves to progress and pumps look
    // permanently parked even when production behaviour is fine.
    const ticks = SIM_SECONDS;
    const settlePerTickMs = 200;
    const realSleep = (ms) => new Promise((r) => setTimeout(r, ms));
    let lastCtrl = pumps.map(() => 0);
    let largeJumpTicks = 0;
    for (let i = 0; i < ticks; i++) {
      for (const p of pumps) injectPumpPressure(p, 19620, 117720);
      ps.setManualInflow(Q_IN, Date.now(), 'm3/s');
      advance(TICK_MS);
      ps.tick();
      await realSleep(settlePerTickMs);

      const states = pumps.map((p) => p.state.getCurrentState());
      const ctrls  = pumps.map((p) => Number(p.state.getCurrentPosition?.()) || 0);

      // Park observation: any pump in 'accelerating'/'decelerating' for
      // more than 3 consecutive seconds at flat ctrl is parked. Cheap
      // approximation: count how often we sample those states.
      for (const s of states) {
        if (s === 'accelerating' || s === 'decelerating') parkObservations += 1;
      }

      // Thrashing observation: ctrl jumping by > 30 % between consecutive
      // seconds (in either direction) suggests retarget churn.
      for (let k = 0; k < pumps.length; k++) {
        if (Math.abs(ctrls[k] - lastCtrl[k]) > 30) largeJumpTicks += 1;
      }
      lastCtrl = ctrls;

      if (i === Math.floor(ticks * 0.66)) {
        console.log(`  tick ${i}/${ticks} states=[${states.join(', ')}] ctrls=[${ctrls.map((c) => c.toFixed(0)).join(', ')}]`);
      }
    }

    // After SIM_MINUTES, system must be in a coherent state: pumps high
    // ctrl, no one parked.
    const finalStates = pumps.map((p) => p.state.getCurrentState());
    const finalCtrls  = pumps.map((p) => Number(p.state.getCurrentPosition?.()) || 0);
    console.log(`  FINAL states=[${finalStates.join(', ')}] ctrls=[${finalCtrls.map((c) => c.toFixed(1)).join(', ')}]`);
    console.log(`  Park observations across ${ticks} ticks×3 pumps: ${parkObservations}`);
    console.log(`  Large-jump tick events (>30 % ctrl change s-to-s): ${largeJumpTicks}`);

    for (const s of finalStates) {
      assert.equal(s, 'operational',
        `final state must be operational under steady high demand; one pump in '${s}'`);
    }
    for (const c of finalCtrls) {
      assert.ok(c > 80, `final ctrl must be >80 % under storm inflow; got ${c.toFixed(1)} %`);
    }
    // Allow some movement transients but not constant retargeting.
    // 3 pumps × 180 ticks = 540 samples; >25 % churn is a thrash signal.
    const maxAllowedJumps = Math.floor(ticks * 3 * 0.25);
    assert.ok(largeJumpTicks < maxAllowedJumps,
      `excessive ctrl thrash: ${largeJumpTicks} large-jump events (max ${maxAllowedJumps}) — system isn't converging`);
  } finally {
    restore();
  }
});