Snapshot WIP: solver HP epic progress, BPHX/HX physics, BMAD skill refresh.

Capture uncommitted solver robustness work (regularization, domain errors, linear solver lifecycle, tube DP/MSH), web workbench updates, and synced BMAD skills across IDE agent folders before starting BPHX pressure-drop.

Co-authored-by: Cursor <cursoragent@cursor.com>

plans/audit-2026-07-remediation-plan.md

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+# Entropyk Audit — Findings & Remediation Plan
+
+**Date**: 2026-07-17
+**Scope**: Full workspace audit (docs vs Rust code, tests, bindings, dead code)
+**Audience**: Executing agent — this document is self-contained. Read it fully before acting.
+
+---
+
+## 0. Project Context You Need
+
+Entropyk is a Rust thermodynamic cycle simulation library (HVAC/R). Workspace layout:
+
+- `crates/core` — physical newtypes (Pressure Pa, Temperature K, Enthalpy J/kg, MassFlow kg/s)
+- `crates/fluids` — `FluidBackend` trait + backends: CoolProp (feature `coolprop`, ON via facade), Tabular (bicubic), Incompressible
+- `crates/components` — all thermodynamic components implementing the `Component` trait
+- `crates/solver` — Newton-Raphson (Armijo line search, Jacobian freezing), Picard fallback, inverse control
+- `crates/entropyk` — facade (SystemBuilder, rating, SimulationResult)
+- `crates/cli` — CLI (8 subcommands: run, batch, validate, qualify, rate, scop, seer, schema)
+- `crates/vendors` — vendor data parsers (Copeland, Danfoss, SWEP, Bitzer)
+- `bindings/{python,c,wasm}` — at repo ROOT (NOT `crates/bindings/` as AGENTS.md claims)
+- `demo/`, `apps/web` (Next.js), `ui/` (dead)
+
+### Key mechanisms (post-CM1.x changes — the source of most test failures)
+
+1. **State vector is `[ṁ, P, h]` per edge** (3 unknowns/edge), formerly `[P, h]`. Docs still say `[P, h]`.
+2. **DoF gate in `System::finalize()`** (`crates/solver/src/system.rs:762-792`): over-constrained systems are REJECTED with `TopologyError::DofImbalance`. This is DELIBERATE. Escape hatch for tests: `set_enforce_dof_gate(false)` on `System`.
+3. **Picard validates squareness**: `crates/solver/src/strategies/sequential_substitution.rs:305-313` returns `InvalidSystem` if `n_state != n_equations`.
+4. **Canonical post-CM1.2 mock pattern** (see `crates/solver/tests/homotopy_continuation.rs`, which PASSES): each mock has 2 equations (P and h) AND implements `port_mass_flows()` providing mass-flow continuity, e.g. `Ok(vec![MassFlow::from_kg_per_s(0.05), MassFlow::from_kg_per_s(-0.05)])`.
+
+### Hard rules for the executing agent
+
+- **NEVER modify production code (`crates/*/src`, `bindings/*/src`) in Steps 1-2** — test-only changes. The DoF gate, the `"newton"` default, and the squareness check are deliberate.
+- Project policy (AGENTS.md): zero-panic, exact Jacobians (no numerical differentiation unless explicitly requested), English for code/comments/docs.
+- Verify with: `cargo test -p <package>` after each file; full `cargo test --workspace --no-fail-fast` at the end of Step 1.
+- Do NOT run `git commit`/`git push` — the user handles git.
+
+---
+
+## 1. Audit Findings Summary
+
+**Good**: workspace compiles cleanly (`cargo check --workspace --all-targets`, only cosmetic warnings). Crate unit tests all pass: components 867, solver lib 290, core 160, entropyk 75, fluids 115, cli lib 57. Solver features (Newton+Armijo, Jacobian freezing, Picard ω=0.5, fallback, Anderson acceleration, homotopy) exist and are individually tested.
+
+**Bad**: ~28 integration tests FAIL in 16 suites (details in §2). Exact-Jacobian policy violated in production (§3). Python/C bindings ship mocked/stubbed physics without any user warning (§4). Various P1/P2 gaps (§5).
+
+---
+
+## 2. STEP 1 — Fix the failing tests (P0-0)
+
+Test failures fall in 3 categories. Category A = obsolete tests after CM1.2/DoF gate (fix tests). Category B = genuine suspects (Step 2, do NOT fix yet). Category C = deliberate default change (update expectations).
+
+### 2.1 Category A — re-balance obsolete mocks
+
+**`crates/entropyk/tests/constraints_api.rs`** — `test_builder_dof_imbalance_two_constraints_one_control` (line ~125): the test does `.build().expect("build should succeed")` then asserts `validate_inverse_control_dof()` fails. With the DoF gate, `build()` now fails first with DofImbalance (5 eqs vs 4 unknowns). **Fix**: rewrite the test to assert `build()` returns the DofImbalance error (the new contract). Keep `test_builder_constraints_link_and_validate_dof` (passes) untouched.
+
+**`crates/entropyk/tests/port_validated_edges.rs`** — `test_build_system_with_port_validated_edges` (line ~201): build fails, 6 eqs vs 5 unknowns (3 mock nodes × 2 eqs). The test targets port validation, not DoF. **Fix**: re-dimension mock `n_eqs` to balance (or, if SystemBuilder exposes it, disable the gate — check first; prefer re-balancing).
+
+**`crates/entropyk/tests/simulation_result.rs`** — `test_realistic_cycle_json_output` (line ~102): finalize fails, 12 eqs vs 10 unknowns (compressor mock 6 eqs, condenser/valve/evap 2 each). **Fix**: adjust mock `n_eqs` to square the system (test targets JSON serialization).
+
+**`crates/solver/tests/fallback_solver.rs`** — 7 failures:
+- `test_fallback_stiff_nonlinear`, `test_timeout_across_switches`, `test_oscillation_prevention_newton_to_picard_stays`, `test_newton_redivergence_commits_to_picard`: `InvalidSystem "State dimension (3) does not match equation count (2)"`. Mock `StiffNonlinearSystem` (line 95) has n=2 cubic equations reading `state[1+i]` but the single self-loop edge yields 3 unknowns. **Fix**: add a 3rd equation for the ṁ slot (index 0, e.g. `r[n] = state[0] - target` with its Jacobian entry), preserving intent (fallback Newton↔Picard on stiff system).
+- `test_fallback_disabled_pure_newton` (~line 227), `test_fallback_both_solvers_can_converge` (~362), `test_fallback_solver_integration` (~631): "Should converge with Newton" — same root cause on `LinearSystem` (line 48) / related mocks. Fix the same way.
+
+**`crates/solver/tests/chiller_air_glycol_integration.rs`** — `test_two_circuit_chiller_topology` (line ~438): 46 eqs vs 36 unknowns (mock at line 104). **Fix**: re-dimension mocks (n_eqs and/or `port_mass_flows`) to balance both circuits.
+
+**`crates/solver/tests/convergence_criteria.rs`** — `test_newton_with_criteria_single_circuit` (line ~283): 4 eqs vs 3 unknowns, `MockConvergingComponent` (line 246). **Fix**: add the ṁ equation or `port_mass_flows`.
+
+**`crates/solver/tests/inverse_control.rs`** — `test_3x3_jacobian_block_is_fully_dense` (line ~1097): 9 eqs vs 7 unknowns, `MockPassThrough` (line 26). **Fix**: balance mocks; preserve the dense-3x3-Jacobian intent.
+
+**`crates/solver/tests/macro_component_integration.rs`** — 5+ tests (`test_4_component_cycle_macro_creation`, `test_two_macro_chillers_in_parallel_topology`, `test_coupling_residuals_nonzero_at_inconsistent_state`, `test_jacobian_coupling_entries_correct`, `test_4_component_cycle_expose_two_ports`): all fail at line ~87, 12 eqs vs 9 unknowns, `PassThrough` mock (line 23). **Fix**: balance the mocks.
+
+**`crates/cli/tests/single_run.rs`** — `test_failed_run_json_includes_failure_diagnostics` (line ~1365): the scenario now fails with an under-constrained DoF error (pump1/pump2, 4 eqs vs 5 unknowns) BEFORE the solver runs, so no `failure_diagnostics` are emitted. The test intent: a run that fails AFTER iterating must include `failure_diagnostics` in the JSON output. **Fix**: change the test config so the system is DoF-square but the SOLVER genuinely fails after some iterations (e.g. physically incompatible constraints or unreachable targets). Read how `failure_diagnostics` is produced in `crates/cli/src` (grep `failure_diagnostics`) and see `crates/solver/tests/failure_diagnostics.rs` (passes) for a working scenario.
+
+### 2.2 Category C — update expectations
+
+**`crates/cli/tests/config_parsing.rs`** — `test_parse_minimal_config` (line 14) and `test_solver_config_defaults` (line 173) expect `strategy == "fallback"`; the deliberate default is `"newton"` (`crates/cli/src/config.rs:444-446`, doc: `"newton"` or `"picard"`). **Fix**: update expectations to `"newton"`.
+
+### 2.3 Step 1 acceptance
+
+`cargo test --workspace --no-fail-fast`: everything green EXCEPT the 4 Category-B tests (§3), which must still fail at this stage.
+
+---
+
+## 3. STEP 2 — Investigate Category B (genuine suspects)
+
+- `crates/solver/tests/inverse_calibration.rs::test_inverse_calibration_f_ua` — `NonConvergence { iterations: 100, final_residual: 9700.0 }`
+- `crates/solver/tests/inverse_calibration_algorithm.rs::test_single_factor_calibration_f_ua` — `ConvergenceFailure { factor: "evaporator.z_ua", iterations: 100, residual_norm: 9700.0 }`
+- `crates/solver/tests/jacobian_freezing.rs::test_frozen_jacobian_converges_cubic_system` and `test_auto_recompute_on_divergence_trend` — hard divergence (`Residual 999700029999 exceeds threshold 10000000000`)
+
+First check whether these are also squareness victims (Category A in disguise). If not: the calibration failures are consistent with FD/incomplete Jacobians (§4) — the evaporator `z_ua` calibration drives a `HeatExchanger` whose Jacobian is 100% finite-difference. Document the root cause; if it is the FD Jacobian, the fix lands with Step 4.
+
+---
+
+## 4. STEP 3 & 4 — Exact Jacobians (P0-1)
+
+### 4.1 Step 3 — Screw compressor (quick win, ~half day)
+
+`crates/components/src/screw_economizer_compressor.rs:570-605` — `jacobian_entries` only emits trivial entries (∂/∂ṁ = ±1, ∂/∂W = ±1). Missing:
+- **Row 3** (`r3 = p_eco_port − √(p_suc·p_dis)`): zero entries. Add ∂r3/∂p_eco = 1, ∂r3/∂p_suc = −0.5·√(p_dis/p_suc), ∂r3/∂p_dis = −0.5·√(p_suc/p_dis). The P column indices must be resolved like the ṁ indices already are (`set_system_context` / port context — check how `suction_m_idx` etc. are wired and mirror it for pressures).
+- **Rows 0, 1, 4**: curve derivatives ∂(m_suc_calc, m_eco_calc, w_calc)/∂(p_suc, p_dis). Curves are 2D polynomials — derive analytically; chain with ∂SST/∂p_suc, ∂SDT/∂p_dis (backend `dT_sat/dP`).
+- Validate with finite-difference tests (pattern already used in the crate's test modules).
+
+### 4.2 Step 4 — `HeatExchanger` generic (1–2 days)
+
+`crates/components/src/heat_exchanger/exchanger.rs:816-865` — in 4-port mode (the only functional mode; otherwise `compute_residuals` errors with `live_state_required_error`), the Jacobian is **100% central finite differences**: 10 columns × 2 residual evaluations, each evaluation triggering up to 4 fluid-backend calls. This kills Newton's quadratic convergence and is the most expensive solver path.
+
+**Fix**: add a `jacobian()` method to the `HeatTransferModel` trait (`crates/components/src/heat_exchanger/model.rs:125`):
+- LMTD and ε-NTU residuals are analytically derivable w.r.t. the 4 ports' (T, ṁ).
+- The only hard part: ∂T/∂(P,h) per fluid. Water/air: 1/Cp. Refrigerants: CoolProp analytic derivatives (`d(T)/d(Hmass)|P`); tabular backend: spline derivatives are free.
+- Wire through `HeatExchanger::jacobian_entries` replacing the FD block. Keep a feature-flagged FD path for cross-checking.
+- Validate: FD-comparison tests + rerun Category-B calibration tests (Step 2) + `cargo test -p entropyk-cli --test hx_standalone` (currently passes in ~29 s — must stay green, and should get faster).
+
+### 4.3 Other FD violations in production (fix after Step 4, same pattern)
+
+- `compressor.rs:1257-1307` (∂r/∂h via FD; also `estimate_density`/`estimate_temperature` at :1632-1705 are hardcoded placeholders bypassing FluidBackend)
+- `pump.rs:593-611`, `pipe.rs:768-774` (polynomial curves — analytically derivable)
+- `anchor.rs:294-313`, `isentropic_compressor.rs:967-1039`, `isenthalpic_expansion_valve.rs:337`
+- `condenser.rs:1301-1311,1384-1392`, `evaporator.rs:1088-1096,1129-1140` (localized `dT_sat/dP` FD — acceptable if backend exposes no analytic derivative; document the justification)
+
+---
+
+## 5. STEP 5 — Binding honesty (P0-2)
+
+### 5.1 The mocks (verified inventory)
+
+**Python** — `crates/components/src/python_components.rs` (14 `Py*Real` classes; ALL have EMPTY `jacobian_entries`):
+
+| Python class | Reality |
+|---|---|
+| `Compressor` | ΔP hardcoded **+1 MPa** (:220); AHRI coeffs m7–m10 and `efficiency` unused; docstring claims "real physics" |
+| `ExpansionValve` | ΔP hardcoded −1 MPa (:327); `opening` parameter validated but NEVER used |
+| `Evaporator` | fixed anchors 3.5 bar / 410 kJ/kg (:477-478); user UA/conditions ignored |
+| `Pipe` | ΔP = 0 (:628, "no pressure drop for testing"); Darcy-Weisbach code exists but `dead_code` |
+| `Pump` / `Fan` | **are `PyPipeReal`** (`bindings/python/src/components.rs:561,606`); `pressure_rise_pa` ignored |
+| `FlowMerger` | unweighted averaging (physically wrong, :948-966) |
+| `FlowSink` | stub, 0 equations |
+| boundaries (Refrigerant/Brine/Air Source/Sink) | REAL — leave alone |
+
+**C** — `bindings/c/src/components.rs`: `compressor_create` (:114), `expansion_valve_create` (:194), `pipe_create` (:257) → `SimpleAdapter`: residuals = 0 (invisible to solver), parameters validated then discarded (`let _ = ahri_coeffs;`). FFI docs claim real behavior. `condenser/evaporator/economizer_create` are REAL.
+
+**Demo**: `demo/src/bin/eurovent.rs:417-420` copies `eurovent_report.html` verbatim — committed hardcoded values presented as simulation output.
+
+### 5.2 Remediation (two phases)
+
+- **Phase A (half day)**: explicit `DeprecationWarning`/`RuntimeWarning` at construction of every mocked Python class stating which physics is mocked; honest docstrings; a printed warning or doc note for the 3 C stubs; mark the Eurovent report as a static sample. No physics changes.
+- **Phase B (2–3 days, after Step 4)**: delegate `Py*Real` to the real Rust components (they all exist) and replace `SimpleAdapter` with real `Compressor`/`ExpansionValve`/`Pipe`. Move `python_components.rs` OUT of `crates/components` into `bindings/python` (dependency inversion).
+
+---
+
+## 6. P1/P2 Backlog (not in scope for immediate execution — record for planning)
+
+1. **Factory divergence**: `crates/cli/src/run.rs::create_component` (33 arms) vs `crates/components/src/registry.rs` — registry lacks IsentropicCompressor, IsenthalpicExpansionValve, ReversingValve, Bphx*, Anchor, HeatSource, ThermalLoad, FreeCoolingExchanger, MchxCondenserCoil, AirCooledCondenser, FinCoilCondenser → `SystemBuilder::to_config_json` output is NOT re-loadable. Unify the two factories.
+2. **Facade gaps**: `crates/entropyk/src/lib.rs` does not re-export `Bphx*`, `FloodedCondenser`, `Economizer`, `Node`, `MovingBoundaryHX` (the latter is implemented, tested, documented — but unreachable). CLI lacks arms for `Economizer`, `FloodedCondenser`, `Node`.
+3. **Silent fallback**: `run.rs:3670` — `"Ahri540" | "AHRI540" | "ahri540" | _` arm swallows ANY typo in `model_type`. Remove the `_`. Also `run.rs:4286` "Supported:" error message is incomplete.
+4. **Dead code**: `crates/components/src/{python_components_clean.rs, python_boundary_append.rs, mode_switch.rs, pump_controller.rs}` (not declared in lib.rs), `crates/components/patch_hx.py`, `bindings/python/src/{types_appended.rs, types_clean.rs}`, `ui/` (calls removed endpoint `/api/calculate`), `demo/{inverse_control_template.html, macro_chiller_schema.html}` (orphans), 5 committed Mach-O arm64 binaries in `bindings/c/tests/`, `bindings/python/{test!entropyk.py, print_eqs.py, test_eq_count.py}`, `crates/solver/tests/_tmp_analytic.rs`, `crates/cli/examples/_ui_repro_flooded_port.json`. `crates/vendors` has zero dependents.
+5. **Docs to sync**: AGENTS.md (`crates/bindings/` → `bindings/`; `uv pip install -e ./bindings/python`), DOCUMENTATION.md (state vector [ṁ,P,h]; `Density` newtype doesn't exist; incompressible ρ is quadratic not linear; phases enum is Liquid/Vapor/TwoPhase/Supercritical), CLI_TUTORIAL.md (references 3 nonexistent example files; missing `qualify`/`schema` commands), `apps/web/README.md` (port 3031 → 3030), `crates/fluids/build.rs:12` (redundant `dylib=coolprop`).
+6. **Zero-panic violations**: production `unwrap()`/`expect()` in condenser.rs (22), evaporator.rs (23), flooded_evaporator.rs (21), exchanger.rs (18), builder.rs (3), coolprop.rs:355,377 (RwLock), coolprop-sys (CString::new).
+7. **Mojibake**: `python_components.rs` has 36 lines with U+FFFD and French comments — violates the English-docs convention.
+
+---
+
+## 7. Execution Order & Validation
+
+| Step | Scope | Effort | Validation |
+|---|---|---|---|
+| 1 | Fix Category A + C tests (test files ONLY) | ½–1 d | `cargo test --workspace --no-fail-fast` — all green except 4 Category-B |
+| 2 | Root-cause Category B (no fixes yet) | ½ d | Written diagnosis; decide if fixed by Step 4 |
+| 3 | Screw compressor analytic Jacobian | ½ d | FD-validation tests + `cargo test -p entropyk-components` |
+| 4 | `HeatTransferModel::jacobian()` + wire-in | 1–2 d | FD-comparison tests; hx_standalone green; Category-B retest |
+| 5A | Binding warnings + honest docs | ½ d | `cargo check --workspace`; manual warning check |
+| 5B+ | Real delegation, factory unification, dead code, docs sync, zero-panic | later | per-item |
+
+**Uncommitted work warning**: the repo currently has ~1470 modified-but-uncommitted files (211 `.rs`, +24 453/−5 698 lines). Recommend the user commits BEFORE starting Step 1 so remediation diffs are reviewable.