""" Integration tests for safety workflow scenarios. Tests safety limit violations, emergency stop workflows, and failsafe mode operations. """ import pytest import pytest_asyncio from unittest.mock import Mock, AsyncMock import asyncio from src.database.flexible_client import FlexibleDatabaseClient from src.core.auto_discovery import AutoDiscovery from src.core.safety import SafetyLimitEnforcer from src.core.emergency_stop import EmergencyStopManager from src.core.setpoint_manager import SetpointManager from src.core.security import SecurityManager from src.core.compliance_audit import ComplianceAuditLogger from src.monitoring.watchdog import DatabaseWatchdog class TestSafetyWorkflows: """Test safety-related workflows and scenarios.""" @pytest_asyncio.fixture async def db_client(self): """Create database client with safety test data.""" client = FlexibleDatabaseClient( database_url="sqlite:///:memory:", pool_size=5, max_overflow=10, pool_timeout=30 ) await client.connect() client.create_tables() # Insert safety test data self._insert_safety_test_data(client) return client def _insert_safety_test_data(self, db_client): """Insert comprehensive safety test data.""" # Insert stations db_client.execute( """INSERT INTO pump_stations (station_id, station_name, location) VALUES ('SAFETY_STATION_001', 'Safety Test Station 1', 'Test Location A'), ('SAFETY_STATION_002', 'Safety Test Station 2', 'Test Location B')""" ) # Insert pumps with different safety configurations db_client.execute( """INSERT INTO pumps (station_id, pump_id, pump_name, control_type, min_speed_hz, max_speed_hz, default_setpoint_hz) VALUES ('SAFETY_STATION_001', 'SAFETY_PUMP_001', 'Safety Pump 1', 'DIRECT_SPEED', 20.0, 60.0, 35.0), ('SAFETY_STATION_001', 'SAFETY_PUMP_002', 'Safety Pump 2', 'LEVEL_CONTROLLED', 25.0, 55.0, 40.0), ('SAFETY_STATION_002', 'SAFETY_PUMP_003', 'Safety Pump 3', 'POWER_CONTROLLED', 30.0, 50.0, 38.0)""" ) # Insert safety limits with different scenarios db_client.execute( """INSERT INTO pump_safety_limits (station_id, pump_id, hard_min_speed_hz, hard_max_speed_hz, hard_min_level_m, hard_max_level_m, emergency_stop_level_m, dry_run_protection_level_m, hard_max_power_kw, hard_max_flow_m3h, max_starts_per_hour, min_run_time_seconds, max_continuous_run_hours, max_speed_change_hz_per_min, set_by, approved_by) VALUES ('SAFETY_STATION_001', 'SAFETY_PUMP_001', 20.0, 60.0, 1.0, 5.0, 0.5, 1.5, 15.0, 200.0, 6, 300, 24, 10.0, 'admin', 'admin'), ('SAFETY_STATION_001', 'SAFETY_PUMP_002', 25.0, 55.0, 1.5, 4.5, 1.0, 2.0, 12.0, 180.0, 6, 300, 24, 10.0, 'admin', 'admin'), ('SAFETY_STATION_002', 'SAFETY_PUMP_003', 30.0, 50.0, 2.0, 4.0, 1.5, 2.5, 10.0, 160.0, 6, 300, 24, 10.0, 'admin', 'admin')""" ) # Insert optimization plans that might trigger safety limits import datetime now = datetime.datetime.now() db_client.execute( f"""INSERT INTO pump_plans (station_id, pump_id, interval_start, interval_end, suggested_speed_hz, target_level_m, target_power_kw, plan_status) VALUES ('SAFETY_STATION_001', 'SAFETY_PUMP_001', '{now}', '{now + datetime.timedelta(hours=1)}', 65.0, 3.0, 12.0, 'ACTIVE'), ('SAFETY_STATION_001', 'SAFETY_PUMP_002', '{now}', '{now + datetime.timedelta(hours=1)}', 15.0, 2.5, 10.0, 'ACTIVE'), ('SAFETY_STATION_002', 'SAFETY_PUMP_003', '{now}', '{now + datetime.timedelta(hours=1)}', 45.0, 3.5, 8.0, 'ACTIVE')""" ) @pytest_asyncio.fixture async def safety_components(self, db_client): """Create safety-related components for testing.""" # Create auto discovery auto_discovery = AutoDiscovery(db_client) await auto_discovery.discover() # Create safety components safety_enforcer = SafetyLimitEnforcer(db_client) emergency_stop_manager = EmergencyStopManager(db_client) # Load safety limits await safety_enforcer.load_safety_limits() # Create mock alert manager for watchdog mock_alert_manager = Mock() watchdog = DatabaseWatchdog(db_client, mock_alert_manager) # Create setpoint manager setpoint_manager = SetpointManager( discovery=auto_discovery, db_client=db_client, safety_enforcer=safety_enforcer, emergency_stop_manager=emergency_stop_manager, watchdog=watchdog ) # Create security components security_manager = SecurityManager() audit_logger = ComplianceAuditLogger(db_client) return { 'auto_discovery': auto_discovery, 'safety_enforcer': safety_enforcer, 'emergency_stop_manager': emergency_stop_manager, 'setpoint_manager': setpoint_manager, 'security_manager': security_manager, 'audit_logger': audit_logger, 'watchdog': watchdog } @pytest.mark.asyncio async def test_safety_limit_violation_workflow(self, safety_components): """Test complete workflow for safety limit violations.""" setpoint_manager = safety_components['setpoint_manager'] safety_enforcer = safety_components['safety_enforcer'] # Test pump with optimization plan that exceeds safety limits station_id = 'SAFETY_STATION_001' pump_id = 'SAFETY_PUMP_001' # Get setpoint (should be enforced to max limit) setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) # Verify setpoint is within safety limits pump_info = setpoint_manager.discovery.get_pump(station_id, pump_id) max_speed = pump_info.get('max_speed_hz', 60.0) # The setpoint should be enforced to the maximum safety limit (60.0) # even though the optimization plan requests 65.0 assert setpoint <= max_speed, f"Setpoint {setpoint} exceeds safety limit {max_speed}" assert setpoint == 60.0, f"Setpoint should be enforced to safety limit, got {setpoint}" @pytest.mark.asyncio async def test_emergency_stop_clearance_workflow(self, safety_components): """Test emergency stop activation and clearance workflow.""" setpoint_manager = safety_components['setpoint_manager'] emergency_stop_manager = safety_components['emergency_stop_manager'] station_id = 'SAFETY_STATION_001' pump_id = 'SAFETY_PUMP_002' # Get normal setpoint normal_setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert normal_setpoint is not None # Activate emergency stop emergency_stop_manager.emergency_stop_pump(station_id, pump_id, "test_workflow") # Verify setpoint is 0 during emergency stop emergency_setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert emergency_setpoint == 0.0, "Setpoint not zero during emergency stop" # Clear emergency stop emergency_stop_manager.clear_emergency_stop_pump(station_id, pump_id, "test_clearance") # Verify setpoint returns to normal recovered_setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert recovered_setpoint == normal_setpoint, "Setpoint did not recover after emergency stop clearance" @pytest.mark.asyncio async def test_multiple_safety_violations(self, safety_components): """Test handling of multiple simultaneous safety violations.""" setpoint_manager = safety_components['setpoint_manager'] safety_enforcer = safety_components['safety_enforcer'] # Test multiple pumps with different safety violations test_cases = [ ('SAFETY_STATION_001', 'SAFETY_PUMP_001', 60.0), # Exceeds max speed (65.0 -> 60.0) ('SAFETY_STATION_001', 'SAFETY_PUMP_002', 25.0), # Below min speed (15.0 -> 25.0) ('SAFETY_STATION_002', 'SAFETY_PUMP_003', 45.0), # Within limits (45.0 -> 45.0) ] for station_id, pump_id, expected_enforced_setpoint in test_cases: setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) # Verify setpoint is within safety limits pump_info = setpoint_manager.discovery.get_pump(station_id, pump_id) min_speed = pump_info.get('min_speed_hz', 20.0) max_speed = pump_info.get('max_speed_hz', 60.0) assert min_speed <= setpoint <= max_speed, \ f"Setpoint {setpoint} out of range [{min_speed}, {max_speed}] for {station_id}/{pump_id}" # Verify specific enforcement assert setpoint == expected_enforced_setpoint, \ f"Setpoint enforcement failed for {station_id}/{pump_id}: expected {expected_enforced_setpoint}, got {setpoint}" @pytest.mark.asyncio async def test_safety_limit_dynamic_updates(self, safety_components, db_client): """Test that safety limit updates are reflected in real-time.""" setpoint_manager = safety_components['setpoint_manager'] safety_enforcer = safety_components['safety_enforcer'] station_id = 'SAFETY_STATION_001' pump_id = 'SAFETY_PUMP_001' # Get initial setpoint (should be limited to 60.0 from the 65.0 plan) initial_setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert initial_setpoint == 60.0, f"Initial setpoint should be limited to 60.0, got {initial_setpoint}" # Update safety limits to be more restrictive db_client.execute( """UPDATE pump_safety_limits SET hard_max_speed_hz = 45.0 WHERE station_id = 'SAFETY_STATION_001' AND pump_id = 'SAFETY_PUMP_001'""" ) # Reload safety limits await safety_enforcer.load_safety_limits() # Get updated setpoint (should now be limited to 45.0) updated_setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) # Verify setpoint is now enforced to new limit assert updated_setpoint == 45.0, f"Setpoint {updated_setpoint} not enforced to new limit 45.0" assert updated_setpoint < initial_setpoint, f"Setpoint should be lower after safety limit update: {updated_setpoint} < {initial_setpoint}" @pytest.mark.asyncio async def test_emergency_stop_cascade_effects(self, safety_components): """Test cascade effects of emergency stops on related systems.""" setpoint_manager = safety_components['setpoint_manager'] emergency_stop_manager = safety_components['emergency_stop_manager'] # Activate station-wide emergency stop station_id = 'SAFETY_STATION_001' emergency_stop_manager.emergency_stop_station(station_id, "station_emergency_test") # Verify all pumps in the station are stopped pumps = setpoint_manager.discovery.get_pumps(station_id) for pump in pumps: pump_id = pump['pump_id'] setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert setpoint == 0.0, f"Pump {pump_id} not stopped during station emergency" # Verify pumps in other stations are unaffected other_station_id = 'SAFETY_STATION_002' other_pumps = setpoint_manager.discovery.get_pumps(other_station_id) for pump in other_pumps: pump_id = pump['pump_id'] setpoint = setpoint_manager.get_current_setpoint(other_station_id, pump_id) assert setpoint > 0.0, f"Pump {pump_id} incorrectly stopped during unrelated station emergency" # Clear station emergency stop emergency_stop_manager.clear_emergency_stop_station(station_id, "station_clearance_test") # Verify pumps return to normal operation for pump in pumps: pump_id = pump['pump_id'] setpoint = setpoint_manager.get_current_setpoint(station_id, pump_id) assert setpoint > 0.0, f"Pump {pump_id} not recovered after station emergency clearance"