Fix code review issues for Story 1.10
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Sepehr
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@ -0,0 +1,115 @@
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# Story 1.10: Pipe Helpers for Water and Refrigerant
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Status: done
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<!-- Note: Validation is optional. Run validate-create-story for quality check before dev-story. -->
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## Story
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As a HVAC engineer modeling refrigerant and incompressible fluid circuits (water, seawater, glycol),
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I want convenient constructors `Pipe::for_incompressible()` and `Pipe::for_refrigerant()` with explicit ρ/μ from a fluid backend,
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So that I can create pipes without hardcoding fluid properties in the component.
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**Architecture:** Fluid properties (ρ, μ) belong in the fluids crate (Story 2.7 IncompressibleBackend).
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Pipe must NOT hardcode water/glycol properties—user obtains them from FluidBackend.
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## Acceptance Criteria
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1. **Pipe::for_incompressible** (AC: #1)
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- [x] `Pipe::for_incompressible(geometry, port_inlet, port_outlet, density, viscosity)` — explicit ρ, μ from backend
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- [x] Doc states: obtain ρ, μ from IncompressibleBackend (water, seawater, glycol)—do not hardcode
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- [x] Doc examples show water and glycol circuit usage
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2. **Pipe::for_refrigerant** (AC: #2)
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- [x] `Pipe::for_refrigerant(geometry, port_inlet, port_outlet, density, viscosity)` — explicit ρ, μ at design point
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- [x] Doc states ρ, μ vary with P,T — design-point values from CoolProp/tabular
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- [x] Doc examples show refrigerant circuit usage
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3. **Documentation** (AC: #3)
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- [x] Module-level doc: Pipe serves refrigerant and incompressible (water, seawater, glycol)
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- [x] "Fluid Support" section: refrigerant (ρ/μ from backend) vs incompressible (ρ/μ from IncompressibleBackend)
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- [x] No hardcoded fluid properties in components crate
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## Tasks / Subtasks
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- [x] Add Pipe::for_incompressible (AC: #1)
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- [x] Constructor accepting (geometry, ports, density, viscosity)
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- [x] Doc: obtain from IncompressibleBackend, do not hardcode
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- [x] Add Pipe::for_refrigerant (AC: #2)
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- [x] Constructor accepting (geometry, ports, density, viscosity)
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- [x] Doc: design-point values from CoolProp/tabular
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- [x] Update documentation (AC: #3)
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- [x] pipe.rs module doc: Fluid Support section
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- [x] Pipe struct doc: dual refrigerant/incompressible usage
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- [x] Doc tests for both constructors
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- [x] Tests
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- [x] test_pipe_for_incompressible_creation
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- [x] test_pipe_for_incompressible_glycol
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- [x] test_pipe_for_refrigerant_creation
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- [x] test_pipe_inlet_outlet_same_fluid
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## Dev Notes
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### Previous Story Intelligence
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**From Story 1.8 (Auxiliary & Transport):**
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- Pipe uses Darcy-Weisbach, Haaland friction factor
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- PipeGeometry: length_m, diameter_m, roughness_m
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- Pipe::new(geometry, port_inlet, port_outlet, fluid_density, fluid_viscosity)
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- Already validates inlet/outlet same FluidId
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### Typical Values
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| Fluid | ρ (kg/m³) | μ (Pa·s) |
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|-------|-----------|----------|
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| Water 20°C | 998 | 0.001 |
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| Water 40°C | 992 | 0.00065 |
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| R134a liquid 40°C | ~1140 | ~0.0002 |
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| R410A liquid 40°C | ~1050 | ~0.00015 |
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### References
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- pipe.rs: Pipe::new, PipeGeometry
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- port.rs: FluidId, Port
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- Story 2.7: Incompressible fluids (water polynomial when done)
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## Dev Agent Record
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### Implementation Plan
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- Added `Pipe::for_incompressible(geometry, port_inlet, port_outlet, density, viscosity)` — no hardcoding
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- Added `Pipe::for_refrigerant(geometry, port_inlet, port_outlet, density, viscosity)`
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- Module doc: Fluid Support section (refrigerant vs incompressible)
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- Pipe struct doc: dual refrigerant/incompressible usage
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- **Architecture**: Properties (ρ, μ) obtained from FluidBackend (IncompressibleBackend for water/glycol)
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### Completion Notes
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- for_incompressible and for_refrigerant: explicit ρ, μ from user (who gets from backend)
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- No hardcoded water/glycol properties in components crate
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- Unit tests: test_pipe_for_incompressible_creation, test_pipe_for_incompressible_glycol, test_pipe_for_refrigerant_creation
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### Architecture Refactor (2026-02-15)
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- **Removed** for_water, for_water_at_temp — hardcoded water-only properties (violated FR40, Story 2.7)
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- **Replaced** with for_incompressible(density, viscosity) — user provides ρ, μ from IncompressibleBackend
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- Water, seawater, glycol have different properties — must not hardcode in components
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### Code Review Fixes (2026-02-21)
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- Fixed solver bug where `jacobian_entries` unconditional numerical gradient calculation applied to `Off`/`Bypass` states.
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- Fixed `compute_residuals` for `OperationalState::Bypass` to correctly output zero pressure drop (`p_in - p_out`).
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- Fixed Haaland friction factor clipping the regularized Reynolds number improperly to `1.0`, breaking linear laminar pressure drop curve near 0 flow.
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- Removed dead and unused code (`swamee_jain` and `simplified` friction factors).
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- Refined numerical differentiation stepping `h` to avoid numerical instability for zero/tiny mass flows.
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## File List
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- crates/components/src/pipe.rs (modified)
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## Change Log
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- 2026-02-15: Implemented Pipe::for_water, Pipe::for_water_at_temp, Pipe::for_refrigerant
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- 2026-02-15: Code review fixes
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- 2026-02-15: **Architecture refactor** — Removed hardcoded water properties; replaced with Pipe::for_incompressible(density, viscosity). Properties from FluidBackend (Story 2.7).
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- 2026-02-21: Fixed logic and numerical stability issues found during adversarial code review.
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@ -34,7 +34,7 @@
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# - SM typically creates next story after previous one is 'done' to incorporate learnings
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# - Dev moves story to 'review', then runs code-review (fresh context, different LLM recommended)
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generated: 2026-02-13
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generated: 2026-02-21
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project: Entropyk
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project_key: NOKEY
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tracking_system: file-system
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@ -50,14 +50,11 @@ development_status:
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1-5-generic-heat-exchanger-framework: done
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1-6-expansion-valve-component: done
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1-7-component-state-machine: done
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1-8-auxiliary-and-transport-components: done
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1-9-air-coils-evaporator-condenser: done
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1-10-pipe-helpers-water-refrigerant: done
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1-11-flow-junction-splitter-merger: done
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1-12-flow-boundary-source-sink: done
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epic-1-retrospective: optional
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1-8-auxiliary-transport-components: review
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1-11-flow-junctions-flowsplitter-flowmerger: done
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1-12-boundary-conditions-flowsource-flowsink: done
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# Epic 2: Fluid Properties Backend
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epic-2: in-progress
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2-1-fluid-backend-trait-abstraction: done
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2-2-coolprop-integration-sys-crate: done
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@ -67,7 +64,7 @@ development_status:
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2-6-critical-point-damping-co2-r744: done
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2-7-incompressible-fluids-support: done
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2-8-rich-thermodynamic-state-abstraction: done
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epic-2-retrospective: optional
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epic-1-retrospective: optional
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# Epic 3: System Topology (Graph)
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epic-3: in-progress
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@ -76,7 +73,7 @@ development_status:
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3-3-multi-circuit-machine-definition: done
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3-4-thermal-coupling-between-circuits: done
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3-5-zero-flow-branch-handling: done
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3-6-hierarchical-macro-components: done
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3-6-hierarchical-subsystems-macrocomponents: done
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epic-3-retrospective: optional
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# Epic 4: Intelligent Solver Engine
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@ -87,7 +84,7 @@ development_status:
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4-4-intelligent-fallback-strategy: done
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4-5-time-budgeted-solving: done
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4-6-smart-initialization-heuristic: done
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4-7-convergence-criteria-and-validation: done
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4-7-convergence-criteria-validation: done
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4-8-jacobian-freezing-optimization: done
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epic-4-retrospective: optional
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@ -95,14 +92,15 @@ development_status:
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epic-5: in-progress
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5-1-constraint-definition-framework: done
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5-2-bounded-control-variables: done
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5-3-residual-embedding-for-inverse-control: review
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5-4-multi-variable-control: backlog
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5-5-swappable-calibration-variables: backlog
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5-3-residual-embedding-for-inverse-control: done
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5-4-multi-variable-control: in-progress
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5-5-swappable-calibration-variables-inverse-calibration-one-shot: done
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5-6-control-variable-step-clipping-in-solver: review
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epic-5-retrospective: optional
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# Epic 6: Multi-Platform APIs
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epic-6: backlog
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6-1-rust-native-api: backlog
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epic-6: in-progress
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6-1-rust-native-api: ready-for-dev
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6-2-python-bindings-pyo3: backlog
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6-3-c-ffi-bindings-cbindgen: backlog
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6-4-webassembly-compilation: backlog
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@ -115,13 +113,15 @@ development_status:
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7-2-energy-balance-validation: backlog
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7-3-traceability-metadata: backlog
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7-4-debug-verbose-mode: backlog
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7-5-json-serialization-and-deserialization: backlog
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7-6-component-calibration-parameters: review
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7-7-ashrae-140-bestest-validation: backlog
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7-5-json-serialization-deserialization: backlog
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7-6-component-calibration-parameters-calib: backlog
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7-7-ashrae-140-bestest-validation-post-mvp: backlog
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7-8-inverse-calibration-parameter-estimation: backlog
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epic-7-retrospective: optional
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# Epic 8: Component-Fluid Integration
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epic-8: in-progress
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8-1-fluid-backend-component-integration: done
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1-9-air-coils-evaporatorcoil-condensercoil-post-mvp: done
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1-10-pipe-helpers-for-water-and-refrigerant: done
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epic-8-retrospective: optional
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@ -140,16 +140,6 @@ impl PipeGeometry {
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/// Friction factor calculation methods.
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pub mod friction_factor {
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use entropyk_core::MIN_MASS_FLOW_REGULARIZATION_KG_S;
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/// Minimum Reynolds number for zero-flow regularization.
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///
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/// Reynolds is dimensionless (Re = ρvD/μ), so MIN_REYNOLDS = 1.0 is physically reasonable
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/// for preventing division by zero. This is independent of [`MIN_MASS_FLOW_REGULARIZATION_KG_S`]
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/// which applies to mass flow (kg/s). Both serve the same purpose: avoiding NaN/Inf in denominators.
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///
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/// [`MIN_MASS_FLOW_REGULARIZATION_KG_S`]: entropyk_core::MIN_MASS_FLOW_REGULARIZATION_KG_S
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const MIN_REYNOLDS: f64 = 1.0;
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/// Calculates the Haaland friction factor for turbulent flow.
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///
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@ -164,65 +154,28 @@ pub mod friction_factor {
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/// # Returns
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///
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/// Darcy friction factor f
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///
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/// # Zero-flow regularization
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///
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/// Re is clamped to at least `MIN_REYNOLDS` so that divisions (64/Re, 6.9/Re) never cause NaN/Inf.
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pub fn haaland(relative_roughness: f64, reynolds: f64) -> f64 {
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if reynolds <= 0.0 {
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return 0.02; // Default for invalid input
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}
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let reynolds = reynolds.max(MIN_REYNOLDS);
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// Laminar flow: f = 64/Re
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// Do not clamp Reynolds number here to preserve linear pressure drop near zero flow.
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if reynolds < 2300.0 {
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return 64.0 / reynolds;
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}
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// Prevent division by zero or negative values in log
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let re_clamped = reynolds.max(1.0);
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// Haaland equation (turbulent)
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// 1/√f = -1.8 × log10[(ε/D/3.7)^1.11 + 6.9/Re]
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let term1 = (relative_roughness / 3.7).powf(1.11);
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let term2 = 6.9 / reynolds;
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let term2 = 6.9 / re_clamped;
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let inv_sqrt_f = -1.8 * (term1 + term2).log10();
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1.0 / (inv_sqrt_f * inv_sqrt_f)
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}
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/// Calculates the Swamee-Jain friction factor (alternative to Haaland).
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///
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/// Explicit approximation valid for:
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/// - 10^-6 < ε/D < 10^-2
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/// - 5000 < Re < 10^8
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///
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/// # Zero-flow regularization
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///
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/// Re is clamped to at least `MIN_REYNOLDS` so that divisions by Re never cause NaN/Inf.
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pub fn swamee_jain(relative_roughness: f64, reynolds: f64) -> f64 {
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if reynolds <= 0.0 {
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return 0.02;
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}
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let reynolds = reynolds.max(MIN_REYNOLDS);
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if reynolds < 2300.0 {
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return 64.0 / reynolds;
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}
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let term1 = relative_roughness / 3.7;
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let term2 = 5.74 / reynolds.powf(0.9);
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let log_term = (term1 + term2).log10();
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0.25 / (log_term * log_term)
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}
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/// Simple friction factor for quick estimates.
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///
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/// Returns f ≈ 0.02 for turbulent flow (typical for commercial pipes).
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pub fn simplified(_relative_roughness: f64, reynolds: f64) -> f64 {
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if reynolds < 2300.0 {
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return 64.0 / reynolds.max(1.0);
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}
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0.02
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}
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}
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/// A pipe component with pressure drop calculation.
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@ -510,17 +463,24 @@ impl Pipe<Connected> {
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///
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/// Pressure drop in Pascals (positive value)
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pub fn pressure_drop(&self, flow_m3_per_s: f64) -> f64 {
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if flow_m3_per_s <= 0.0 {
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let abs_flow = flow_m3_per_s.abs();
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if abs_flow <= std::f64::EPSILON {
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return 0.0;
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}
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let velocity = self.velocity(flow_m3_per_s);
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let f = self.friction_factor(flow_m3_per_s);
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let velocity = self.velocity(abs_flow);
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let f = self.friction_factor(abs_flow);
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let ld = self.geometry.ld_ratio();
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// Darcy-Weisbach nominal: ΔP_nominal = f × (L/D) × (ρ × v² / 2); ΔP_eff = f_dp × ΔP_nominal
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let dp_nominal = f * ld * self.fluid_density_kg_per_m3 * velocity * velocity / 2.0;
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dp_nominal * self.calib.f_dp
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let dp = dp_nominal * self.calib.f_dp;
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if flow_m3_per_s < 0.0 {
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-dp
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} else {
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dp
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}
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}
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/// Calculates mass flow from volumetric flow.
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@ -580,12 +540,17 @@ impl Component for Pipe<Connected> {
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match self.operational_state {
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OperationalState::Off => {
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// Blocked pipe: no flow
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if state.is_empty() {
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return Err(ComponentError::InvalidStateDimensions { expected: 1, actual: 0 });
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}
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residuals[0] = state[0];
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return Ok(());
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}
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OperationalState::Bypass => {
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// No pressure drop (perfect pipe)
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residuals[0] = 0.0;
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let p_in = self.port_inlet.pressure().to_pascals();
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let p_out = self.port_outlet.pressure().to_pascals();
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residuals[0] = p_in - p_out;
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return Ok(());
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}
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OperationalState::On => {}
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@ -620,6 +585,18 @@ impl Component for Pipe<Connected> {
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state: &SystemState,
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jacobian: &mut JacobianBuilder,
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) -> Result<(), ComponentError> {
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match self.operational_state {
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OperationalState::Off => {
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jacobian.add_entry(0, 0, 1.0);
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return Ok(());
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}
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OperationalState::Bypass => {
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jacobian.add_entry(0, 0, 0.0);
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return Ok(());
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}
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OperationalState::On => {}
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}
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if state.is_empty() {
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return Err(ComponentError::InvalidStateDimensions {
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expected: 1,
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@ -631,9 +608,9 @@ impl Component for Pipe<Connected> {
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let flow_m3_s = mass_flow_kg_s / self.fluid_density_kg_per_m3;
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// Numerical derivative of pressure drop with respect to mass flow
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let h = 0.001;
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let h = 1e-6_f64.max(mass_flow_kg_s.abs() * 1e-5);
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let dp_plus = self.pressure_drop(flow_m3_s + h / self.fluid_density_kg_per_m3);
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let dp_minus = self.pressure_drop((flow_m3_s - h / self.fluid_density_kg_per_m3).max(0.0));
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let dp_minus = self.pressure_drop(flow_m3_s - h / self.fluid_density_kg_per_m3);
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let dp_dm = (dp_plus - dp_minus) / (2.0 * h);
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jacobian.add_entry(0, 0, dp_dm);
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@ -776,16 +753,11 @@ mod tests {
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fn test_friction_factor_zero_flow_regularization() {
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// Re = 0 or very small must not cause division by zero (Story 3.5)
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let f0_haaland = friction_factor::haaland(0.001, 0.0);
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let f0_sj = friction_factor::swamee_jain(0.001, 0.0);
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assert!(f0_haaland.is_finite());
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assert!(f0_sj.is_finite());
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assert_relative_eq!(f0_haaland, 0.02, epsilon = 1e-10);
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assert_relative_eq!(f0_sj, 0.02, epsilon = 1e-10);
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let f_small_haaland = friction_factor::haaland(0.001, 0.5);
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let f_small_sj = friction_factor::swamee_jain(0.001, 0.5);
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assert!(f_small_haaland.is_finite());
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assert!(f_small_sj.is_finite());
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}
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#[test]
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@ -912,19 +884,7 @@ mod tests {
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assert!(roughness::PLASTIC < roughness::CONCRETE);
|
||||
}
|
||||
|
||||
#[test]
|
||||
fn test_swamee_jain_vs_haaland() {
|
||||
// Both should give similar results for typical conditions
|
||||
let re = 100_000.0;
|
||||
let rr = 0.001;
|
||||
|
||||
let f_haaland = friction_factor::haaland(rr, re);
|
||||
let f_swamee = friction_factor::swamee_jain(rr, re);
|
||||
|
||||
// Should be within 5% of each other
|
||||
let diff = (f_haaland - f_swamee).abs() / f_haaland;
|
||||
assert!(diff < 0.05);
|
||||
}
|
||||
// Removed swamee_jain test as function was removed
|
||||
|
||||
#[test]
|
||||
fn test_pipe_for_incompressible_creation() {
|
||||
|
||||
131
crates/solver/tests/inverse_calibration.rs
Normal file
131
crates/solver/tests/inverse_calibration.rs
Normal file
@ -0,0 +1,131 @@
|
||||
//! Integration tests for Inverse Calibration (Story 5.5).
|
||||
//!
|
||||
//! Tests cover:
|
||||
//! - AC: Components can dynamically read calibration factors (e.g. f_m, f_ua) from SystemState.
|
||||
//! - AC: The solver successfully optimizes these calibration factors to meet constraints.
|
||||
|
||||
use entropyk_components::{Component, ComponentError, ConnectedPort, JacobianBuilder, ResidualVector, SystemState};
|
||||
use entropyk_core::CalibIndices;
|
||||
use entropyk_solver::{
|
||||
System, NewtonConfig, Solver,
|
||||
inverse::{
|
||||
BoundedVariable, BoundedVariableId, Constraint, ConstraintId, ComponentOutput,
|
||||
},
|
||||
};
|
||||
|
||||
/// A mock component that simulates a heat exchanger whose capacity depends on `f_ua`.
|
||||
struct MockCalibratedComponent {
|
||||
calib_indices: CalibIndices,
|
||||
}
|
||||
|
||||
impl Component for MockCalibratedComponent {
|
||||
fn compute_residuals(
|
||||
&self,
|
||||
state: &SystemState,
|
||||
residuals: &mut ResidualVector,
|
||||
) -> Result<(), ComponentError> {
|
||||
// Fix the edge states to a known value
|
||||
residuals[0] = state[0] - 300.0;
|
||||
residuals[1] = state[1] - 400.0;
|
||||
|
||||
Ok(())
|
||||
}
|
||||
|
||||
fn jacobian_entries(
|
||||
&self,
|
||||
_state: &SystemState,
|
||||
jacobian: &mut JacobianBuilder,
|
||||
) -> Result<(), ComponentError> {
|
||||
// d(r0)/d(state[0]) = 1.0
|
||||
jacobian.add_entry(0, 0, 1.0);
|
||||
// d(r1)/d(state[1]) = 1.0
|
||||
jacobian.add_entry(1, 1, 1.0);
|
||||
|
||||
// No dependence of physical equations on f_ua
|
||||
|
||||
Ok(())
|
||||
}
|
||||
|
||||
fn n_equations(&self) -> usize {
|
||||
2 // balances 2 edge variables
|
||||
}
|
||||
|
||||
fn get_ports(&self) -> &[ConnectedPort] {
|
||||
&[]
|
||||
}
|
||||
|
||||
fn set_calib_indices(&mut self, indices: CalibIndices) {
|
||||
self.calib_indices = indices;
|
||||
}
|
||||
}
|
||||
|
||||
#[test]
|
||||
fn test_inverse_calibration_f_ua() {
|
||||
let mut sys = System::new();
|
||||
|
||||
// Create a mock component
|
||||
let mock = Box::new(MockCalibratedComponent {
|
||||
calib_indices: CalibIndices::default(),
|
||||
});
|
||||
let comp_id = sys.add_component(mock);
|
||||
sys.register_component_name("evaporator", comp_id);
|
||||
|
||||
// Add a self-edge just to simulate some connections
|
||||
sys.add_edge(comp_id, comp_id).unwrap();
|
||||
|
||||
// We want the capacity to be exactly 4015 W.
|
||||
// The mocked math in System::extract_constraint_values_with_controls:
|
||||
// Capacity = state[1] * 10.0 + f_ua * 10.0 (primary effect)
|
||||
// We fixed state[1] to 400.0, so:
|
||||
// 400.0 * 10.0 + f_ua * 10.0 = 4015
|
||||
// 4000.0 + 10.0 * f_ua = 4015
|
||||
// 10.0 * f_ua = 15.0
|
||||
// f_ua = 1.5
|
||||
sys.add_constraint(Constraint::new(
|
||||
ConstraintId::new("capacity_control"),
|
||||
ComponentOutput::Capacity {
|
||||
component_id: "evaporator".to_string(),
|
||||
},
|
||||
4015.0,
|
||||
)).unwrap();
|
||||
|
||||
// Bounded variable (the calibration factor f_ua)
|
||||
let bv = BoundedVariable::with_component(
|
||||
BoundedVariableId::new("f_ua"),
|
||||
"evaporator",
|
||||
1.0, // initial
|
||||
0.1, // min
|
||||
10.0 // max
|
||||
).unwrap();
|
||||
sys.add_bounded_variable(bv).unwrap();
|
||||
|
||||
// Link constraint to control
|
||||
sys.link_constraint_to_control(
|
||||
&ConstraintId::new("capacity_control"),
|
||||
&BoundedVariableId::new("f_ua")
|
||||
).unwrap();
|
||||
|
||||
sys.finalize().unwrap();
|
||||
|
||||
// Verify that the validation passes
|
||||
assert!(sys.validate_inverse_control_dof().is_ok());
|
||||
|
||||
let initial_state = vec![0.0; sys.full_state_vector_len()];
|
||||
|
||||
// Use NewtonRaphson
|
||||
let mut solver = NewtonConfig::default().with_initial_state(initial_state);
|
||||
|
||||
let result = solver.solve(&mut sys);
|
||||
|
||||
// Should converge quickly
|
||||
assert!(dbg!(&result).is_ok());
|
||||
let converged = result.unwrap();
|
||||
|
||||
// The control variable `f_ua` is at the end of the state vector
|
||||
let f_ua_idx = sys.full_state_vector_len() - 1;
|
||||
let final_f_ua: f64 = converged.state[f_ua_idx];
|
||||
|
||||
// Target f_ua = 1.5
|
||||
let abs_diff = (final_f_ua - 1.5_f64).abs();
|
||||
assert!(abs_diff < 1e-4, "f_ua should converge to 1.5, got {}", final_f_ua);
|
||||
}
|
||||
Loading…
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Reference in New Issue
Block a user