Predicted-volume hard-floor at 0 + spill flow position refactor

Volume integrator changes:
- Hard physical floor at 0 added to _updatePredictedVolume. Without
  it, a basin seeded below dryRunSafetyVol (calibration / startup
  / low seed) under continued net-outflow drifted volume arbitrarily
  negative; the level output looked clamped only because
  _calcLevelFromVolume floors at 0, masking the underlying drift.
- New cumulative diagnostic: underflowVolume.predicted.atequipment
  (m³) + getOutput().predictedUnderflowVolume. Non-zero indicates a
  flow-balance error (over-reported outflow / missing inflow).
- The transition-only dryRunSafetyVol clamp is preserved so
  startup-from-empty doesn't snap to 2.1 m³ on tick 1.

Spill flow refactor (taxonomic + bug fix):
- Synthetic spill moved from flow.predicted.out.<child='overflow'>
  to its own position flow.predicted.overflow.<default>. The spill
  is a derived quantity, not a physical sub-source sharing a position
  with pumps — .child() was the wrong knob.
- Removes the spillPrev self-subtraction in the integrator (no longer
  needed: outflowTotal at ['out','downstream'] cleanly excludes spill).
- Closes a latent fall-through bug exposed during this work:
  .child('overflow').getCurrentValue() returned the value of any
  available sibling child when overflow itself didn't yet exist.
  Hardened separately in generalFunctions@a516c2b.
- _selectBestNetFlow folds the overflow position into the outflow
  side so the predicted net-flow balance still reads ~0 while pinned.

Tests: 70/70 pass. 4 new subtests cover the 0-floor, accumulated
underflow tracking, getOutput surface, and refill-from-empty.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

src/specificClass.js

@@ -645,15 +645,13 @@ class PumpingStation {
     const flowUnit = 'm3/s'; // this has to be in m3/s for the actions below
     const now = Date.now();
 
+    // The synthetic spill flow lives at its OWN position ('overflow') —
+    // not as a child of 'out'. That keeps it out of the operational-outflow
+    // sum here (which only sees pumps + downstream measurements), so no
+    // self-subtraction is needed. _selectBestNetFlow folds it back in for
+    // net-flow balance while pinned at overflow.
     const inflow = this.measurements.sum('flow', 'predicted', this.flowPositions.inflow, flowUnit) || 0;
-    const outflowTotal = this.measurements.sum('flow', 'predicted', this.flowPositions.outflow, flowUnit) || 0;
+    const outflowReal = this.measurements.sum('flow', 'predicted', this.flowPositions.outflow, flowUnit) || 0;
-    // Subtract the previous tick's synthetic spill so it doesn't feed back into the integrator.
-    // The spill is registered as a 'predicted out' flow (child='overflow') so _selectBestNetFlow
-    // sees it for net-flow balance, but the volume math here must use REAL outflow only.
-    const spillPrev = this.measurements
-      .type('flow').variant('predicted').position('out').child('overflow')
-      .getCurrentValue(flowUnit) || 0;
-    const outflowReal = outflowTotal - spillPrev;
 
     if (!this._predictedFlowState) {
       this._predictedFlowState = { inflow, outflow: outflowReal, lastTimestamp: now };
@@ -673,12 +671,17 @@ class PumpingStation {
     const writeTimestamp = timestampPrev + deltaSeconds * 1000;
 
     // Predicted-volume bounds.
-    //   Upper: maxVolAtOverflow — past this the basin is physically spilling
+    //   Upper (hard physical):  maxVolAtOverflow — past this the basin spills
-    //          over the weir, so predicted level pins at overflowLevel and
+    //          over the weir; predicted level pins at overflowLevel and the
-    //          the excess is tracked as overflow volume + spill flow.
+    //          excess is tracked as overflow volume + spill flow.
-    //   Lower: dryRunSafetyVol — pumps physically can't pump below this.
+    //   Lower (operational):    dryRunSafetyVol — where pumps must stop. Only
-    // Only a measured level can show level outside this range (e.g. inflow
+    //          clamps on transition from above; a basin seeded below (e.g.
-    // exceeds pump+weir capacity → ceiling-pressure case).
+    //          startup-from-empty) is left alone so it can fill from 0.
+    //   Lower (hard physical):  0 — basin cannot hold negative water. Always
+    //          clamps. Without this, a seeded-low basin under continued
+    //          net-outflow integrates volume arbitrarily negative (the level
+    //          output looks fine because _calcLevelFromVolume floors at 0,
+    //          masking the underlying drift).
     const safety = this._computeSafetyPoints();
     const upperClamp = this.basin.maxVolAtOverflow;
     const lowerClamp = Math.max(0, safety.dryRunSafetyVol ?? 0);
@@ -686,27 +689,29 @@ class PumpingStation {
     const proposedVolume = currentVolume + netVolumeChange;
     let nextVolume = proposedVolume;
     let overflowIncrement = 0;
+    let underflowIncrement = 0;
     if (proposedVolume > upperClamp) {
       overflowIncrement = proposedVolume - upperClamp;
       nextVolume = upperClamp;
     } else if (proposedVolume < lowerClamp && currentVolume >= lowerClamp) {
-      // Drained across the dry-run threshold — pumps would have stopped here.
-      // If we were already below (via calibration / low seed), leave the
-      // integrator alone so it follows the physics it's been told.
       nextVolume = lowerClamp;
     }
+    if (nextVolume < 0) {
+      underflowIncrement = -nextVolume;
+      nextVolume = 0;
+    }
 
-    // Synthetic spill flow.
+    // Synthetic spill flow at position 'overflow'.
-    // While pinned at overflow with continuing net-positive inflow, the
+    // While pinned at upper bound with continuing net-positive inflow, the
-    // weir is carrying away (inflow − outflowReal). Registering this as
+    // weir is carrying away (inflow − outflowReal). _selectBestNetFlow folds
-    // an 'out' flow keeps the predicted net-flow balance at ~0 (matches
+    // this into the outflow side so the predicted net-flow balance reads ~0
-    // the level-pinned reality).
+    // (matches the level-pinned reality).
     let spillRate = 0;
     if (nextVolume >= upperClamp - 1e-9 && (inflow - outflowReal) > this.flowThreshold) {
       spillRate = inflow - outflowReal;
     }
     this.measurements
-      .type('flow').variant('predicted').position('out').child('overflow')
+      .type('flow').variant('predicted').position('overflow')
       .value(spillRate, writeTimestamp, 'm3/s').unit('m3/s');
 
     // Cumulative overflow volume — for compliance reporting via InfluxDB.
@@ -718,6 +723,19 @@ class PumpingStation {
         .value(prevCumulative + overflowIncrement, writeTimestamp, 'm3').unit('m3');
     }
 
+    // Cumulative integrator underflow — diagnostic, NOT compliance.
+    // A nonzero value means the predicted-volume integrator tried to go
+    // below the physical floor (negative water). Root causes are usually
+    // upstream: outflow over-reported (sensor drift, pump curve too
+    // optimistic) or an inflow source missing from the measurement set.
+    if (underflowIncrement > 0) {
+      const prevUnderflow = this.measurements
+        .type('underflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3') ?? 0;
+      this.measurements
+        .type('underflowVolume').variant('predicted').position('atequipment')
+        .value(prevUnderflow + underflowIncrement, writeTimestamp, 'm3').unit('m3');
+    }
+
     this.measurements
       .type('volume').variant('predicted').position('atequipment')
       .value(nextVolume, writeTimestamp, 'm3').unit('m3');
@@ -756,7 +774,12 @@ class PumpingStation {
       if (!bucket || Object.keys(bucket).length === 0) continue;
 
       const inflow = this.measurements.sum(type, variant, this.flowPositions.inflow, unit) || 0;
-      const outflow = this.measurements.sum(type, variant, this.flowPositions.outflow, unit) || 0;
+      const outflowReal = this.measurements.sum(type, variant, this.flowPositions.outflow, unit) || 0;
+      // Fold synthetic spill (position 'overflow') into the outflow side.
+      // It only exists for the predicted variant and only while pinned, so
+      // for measured this is 0.
+      const spill = this.measurements.sum(type, variant, ['overflow'], unit) || 0;
+      const outflow = outflowReal + spill;
       if (Math.abs(inflow) < this.flowThreshold && Math.abs(outflow) < this.flowThreshold) continue;
 
       const net = inflow - outflow;
@@ -1099,7 +1122,9 @@ class PumpingStation {
     output.predictedOverflowVolume = this.measurements
       .type('overflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3') ?? 0;
     output.predictedOverflowRate = this.measurements
-      .type('flow').variant('predicted').position('out').child('overflow').getCurrentValue('m3/s') ?? 0;
+      .type('flow').variant('predicted').position('overflow').getCurrentValue('m3/s') ?? 0;
+    output.predictedUnderflowVolume = this.measurements
+      .type('underflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3') ?? 0;
     return output;
   }
 

test/basic/specificClass.test.js

@@ -472,7 +472,7 @@ test('Predicted volume — overflow clamp and spill tracking', async (t) => {
     assert.equal(vol, 45);  // pinned at overflow
     const cumulative = ps.measurements.type('overflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3');
     assert.equal(cumulative, 1);  // proposed=44+2=46, excess=1 m³ this tick
-    const spill = ps.measurements.type('flow').variant('predicted').position('out').child('overflow').getCurrentValue('m3/s');
+    const spill = ps.measurements.type('flow').variant('predicted').position('overflow').getCurrentValue('m3/s');
     assert.equal(spill, 2);  // instantaneous balance: inflow − outflowReal
   });
 
@@ -483,7 +483,7 @@ test('Predicted volume — overflow clamp and spill tracking', async (t) => {
     assert.equal(vol, 45);
     const cumulative = ps.measurements.type('overflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3');
     assert.equal(cumulative, 3);  // 1 + 2
-    const spill = ps.measurements.type('flow').variant('predicted').position('out').child('overflow').getCurrentValue('m3/s');
+    const spill = ps.measurements.type('flow').variant('predicted').position('overflow').getCurrentValue('m3/s');
     assert.equal(spill, 2);
   });
 
@@ -499,7 +499,7 @@ test('Predicted volume — overflow clamp and spill tracking', async (t) => {
     ps._predictedFlowState = { inflow: 0, outflow: 0, lastTimestamp: t0 + 2000 };
     Date.now = () => t0 + 3000;
     ps._updatePredictedVolume();
-    const spill = ps.measurements.type('flow').variant('predicted').position('out').child('overflow').getCurrentValue('m3/s');
+    const spill = ps.measurements.type('flow').variant('predicted').position('overflow').getCurrentValue('m3/s');
     assert.equal(spill, 0);
     // Volume stays at 45 (no draining force) but is no longer "pinned".
     const vol = ps.measurements.type('volume').variant('predicted').position('atequipment').getCurrentValue('m3');
@@ -549,3 +549,53 @@ test('getOutput — exposes predictedOverflowVolume / predictedOverflowRate', ()
   assert.equal(out.predictedOverflowVolume, 1);
   assert.equal(out.predictedOverflowRate, 2);
 });
+
+// Hard physical floor at 0. The dryRunSafetyVol clamp only fires on transition
+// from above, so a basin seeded below + continued outflow used to integrate
+// the volume arbitrarily negative. The level helper masked this by flooring
+// at 0 in _calcLevelFromVolume — fix is to floor the integrator itself.
+test('Predicted volume — physical floor at 0 (underflow track)', async (t) => {
+  const ps = new PumpingStation(makeConfig({
+    safety: { enableDryRunProtection: true, dryRunThresholdPercent: 5 },
+  }));
+  const t0 = 1_700_000_000_000;
+
+  await t.test('seeded below dryRun + continued outflow does NOT go negative', () => {
+    ps.calibratePredictedVolume(0.5, t0);  // below dryRunSafetyVol (2.1)
+    ps.setManualOutflow(2, t0, 'm3/s');     // 2 m³/s for 1s → would drop to -1.5
+    ps._predictedFlowState = { inflow: 0, outflow: 2, lastTimestamp: t0 };
+    Date.now = () => t0 + 1000;
+    ps._updatePredictedVolume();
+    const vol = ps.measurements.type('volume').variant('predicted').position('atequipment').getCurrentValue('m3');
+    assert.equal(vol, 0);  // floored at 0, not -1.5
+    const underflow = ps.measurements
+      .type('underflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3');
+    assert.equal(underflow, 1.5);  // tracked as diagnostic
+  });
+
+  await t.test('subsequent ticks accumulate underflow while outflow continues', () => {
+    Date.now = () => t0 + 2000;
+    ps._predictedFlowState = { inflow: 0, outflow: 2, lastTimestamp: t0 + 1000 };
+    ps._updatePredictedVolume();
+    const vol = ps.measurements.type('volume').variant('predicted').position('atequipment').getCurrentValue('m3');
+    assert.equal(vol, 0);
+    const underflow = ps.measurements
+      .type('underflowVolume').variant('predicted').position('atequipment').getCurrentValue('m3');
+    assert.equal(underflow, 3.5);  // 1.5 + 2.0
+  });
+
+  await t.test('getOutput exposes predictedUnderflowVolume', () => {
+    const out = ps.getOutput();
+    assert.equal(out.predictedUnderflowVolume, 3.5);
+  });
+
+  await t.test('inflow returns and basin refills from 0 (no jump to dryRunSafetyVol)', () => {
+    ps.setManualInflow(1, t0 + 2000, 'm3/s');
+    ps.setManualOutflow(0, t0 + 2000, 'm3/s');
+    ps._predictedFlowState = { inflow: 1, outflow: 0, lastTimestamp: t0 + 2000 };
+    Date.now = () => t0 + 3000;
+    ps._updatePredictedVolume();
+    const vol = ps.measurements.type('volume').variant('predicted').position('atequipment').getCurrentValue('m3');
+    assert.ok(Math.abs(vol - 1) < 1e-9);  // 0 + 1 = 1, NOT pinned to 2.1
+  });
+});