Add process safety functionality by EvenSol · Pull Request #1614 · equinor/neqsim

EvenSol · 2025-11-01T09:31:19Z

No description provided.

…yzer-package Add process safety analyzer and scenario support

…or-extended-limits Add configurable mechanical design limits and validation

…icaldesign-for-sizing-strategies Refactor safety valve design to support scenario-based sizing

…-for-safety-metrics Add process safety reporting builder and integration tests

…city-methods

…n-and-capacity-methods Add flare disposal network analysis and reporting DTOs

Fix Javadoc warnings and errors

…est-compilation-errors Enhance process safety analyzer scenario support

Copilot

Pull Request Overview

This pull request introduces a comprehensive process safety analysis framework with mechanical design validation, scenario-based safety reporting, and enhanced safety valve sizing capabilities. The changes add support for CSV-based design data loading, multi-scenario relief valve calculations, and disposal network analysis for flare systems.

Reviewed Changes

Copilot reviewed 40 out of 40 changed files in this pull request and generated 3 comments.

Show a summary per file

File	Description
src/test/resources/design_limits_test.csv	Test data file for mechanical design limits
src/test/java/.../ProcessSafetyReportBuilderTest.java	Integration tests for safety report generation
src/test/java/.../ProcessSafetyAnalyzerTest.java	Tests for safety scenario analyzer
src/test/java/.../MechanicalDesignDataSourceTest.java	Tests for CSV design data loading
src/test/java/.../SafetyValveMechanicalDesignTest.java	Enhanced tests for multi-scenario valve sizing
src/main/java/.../safety/*	New safety analysis domain model and DTOs
src/main/java/.../mechanicaldesign/*	Design limit validation and data source framework
src/main/java/.../valve/SafetyValveMechanicalDesign.java	Multi-scenario valve sizing with strategy pattern
src/main/java/.../valve/SafetyValve.java	Scenario management for relief valves
src/main/java/.../flare/Flare.java	Radiation, dispersion, and capacity analysis

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Copilot · 2025-11-01T09:52:39Z

src/test/java/neqsim/process/mechanicaldesign/MechanicalDesignDataSourceTest.java

+    design.setMinOperationPressure(15.0);
+    design.setMaxOperationTemperature(360.0);
+    design.setMinOperationTemperature(265.0);
+    design.setCorrosionAllowanse(3.5);


The method name 'setCorrosionAllowanse' contains a typo. It should be 'setCorrosionAllowance' (with 'ance' instead of 'anse'). This appears to be calling an existing misspelled method in the codebase.

Copilot · 2025-11-01T09:52:40Z

src/test/java/neqsim/process/mechanicaldesign/MechanicalDesignDataSourceTest.java

+    design.setMinOperationPressure(7.0);
+    design.setMaxOperationTemperature(370.0);
+    design.setMinOperationTemperature(270.0);
+    design.setCorrosionAllowanse(6.5);


The method name 'setCorrosionAllowanse' contains a typo. It should be 'setCorrosionAllowance' (with 'ance' instead of 'anse'). This appears to be calling an existing misspelled method in the codebase.

Copilot · 2025-11-01T09:52:40Z

src/main/java/neqsim/process/equipment/flare/Flare.java

+    double referenceMassRate = inStream != null ? inStream.getFlowRate("kg/sec") : 0.0;
+    double standardVolumeRate = 0.0;
+    if (referenceMassRate > 1.0e-12) {
+      double refStdVolume = inStream.getFlowRate("Sm3/sec");


Variable inStream may be null at this access as suggested by this null guard.
Variable inStream may be null at this access as suggested by this null guard.

Suggested change

double refStdVolume = inStream.getFlowRate("Sm3/sec");

double refStdVolume = (inStream != null) ? inStream.getFlowRate("Sm3/sec") : 0.0;

Make safety valve sizing strategies serializable

Fix corrosion allowance naming typo

codecov-commenter · 2025-11-01T10:28:20Z

Codecov Report

❌ Patch coverage is 54.33125% with 659 lines in your changes missing coverage. Please review.
✅ Project coverage is 47.35%. Comparing base (d3e8682) to head (5d7bf5d).

Files with missing lines	Patch %	Lines
...ain/java/neqsim/process/equipment/flare/Flare.java	16.86%	135 Missing and 3 partials ⚠️
...in/java/neqsim/process/safety/DisposalNetwork.java	3.84%	75 Missing ⚠️
...util/report/safety/ProcessSafetyReportBuilder.java	59.21%	43 Missing and 19 partials ⚠️
...esign/data/DatabaseMechanicalDesignDataSource.java	17.39%	34 Missing and 4 partials ⚠️
...a/neqsim/process/safety/ProcessSafetyScenario.java	64.21%	28 Missing and 6 partials ⚠️
...va/neqsim/process/equipment/valve/SafetyValve.java	65.97%	27 Missing and 6 partials ⚠️
...sim/process/mechanicaldesign/MechanicalDesign.java	68.13%	20 Missing and 9 partials ⚠️
...ocess/equipment/flare/dto/FlarePerformanceDTO.java	0.00%	25 Missing ⚠️
...rocess/util/report/safety/ProcessSafetyReport.java	82.22%	10 Missing and 14 partials ⚠️
.../process/equipment/flare/dto/FlareCapacityDTO.java	0.00%	22 Missing ⚠️
... and 18 more

Additional details and impacted files

@@             Coverage Diff              @@
##             master    #1614      +/-   ##
============================================
+ Coverage     47.17%   47.35%   +0.17%     
- Complexity     8917     9121     +204     
============================================
  Files           859      879      +20     
  Lines         84786    86204    +1418     
  Branches      10713    10875     +162     
============================================
+ Hits          39999    40823     +824     
- Misses        41810    42310     +500     
- Partials       2977     3071      +94

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…-to-isblank Fix Java 8 compatibility by avoiding String.isBlank

…processsafetyreportbuildertest

EvenSol added 13 commits November 1, 2025 10:16

Add process safety analyzer and scenario support

b6ada58

Add configurable mechanical design limits and validation

79eb56a

Refactor safety valve sizing strategies

660a335

Add flare capacity metrics and disposal network analysis

ece2a72

Add process safety reporting module and tests

8aac8bc

Merge pull request #245 from EvenSol/codex/create-process-safety-anal…

fbe5876

…yzer-package Add process safety analyzer and scenario support

Merge pull request #246 from EvenSol/codex/enhance-mechanicaldesign-f…

cf7bb94

…or-extended-limits Add configurable mechanical design limits and validation

Merge pull request #247 from EvenSol/codex/refactor-safetyvalvemechan…

d7f14a2

…icaldesign-for-sizing-strategies Refactor safety valve design to support scenario-based sizing

Merge pull request #249 from EvenSol/codex/implement-reporting-module…

da69932

…-for-safety-metrics Add process safety reporting builder and integration tests

Add missing Javadoc tags for legacy APIs

8d8cef9

Improve disposal load estimation for missing data

93e8467

Merge branch 'master' into codex/extend-flare-with-radiation-and-capa…

b42e20b

…city-methods

Merge pull request #248 from EvenSol/codex/extend-flare-with-radiatio…

680a792

…n-and-capacity-methods Add flare disposal network analysis and reporting DTOs

EvenSol marked this pull request as ready for review November 1, 2025 09:31

EvenSol added 4 commits November 1, 2025 10:35

Fix Javadoc warnings and errors

4644005

Merge pull request #250 from EvenSol/codex/fix-javadoc-generation-errors

740fc5c

Fix Javadoc warnings and errors

Enhance process safety analyzer scenario support

0ca5837

Merge pull request #251 from EvenSol/codex/fix-processsafetyanalyzert…

f6408ef

…est-compilation-errors Enhance process safety analyzer scenario support

EvenSol requested a review from Copilot November 1, 2025 09:49

Copilot AI reviewed Nov 1, 2025

View reviewed changes

EvenSol added 4 commits November 1, 2025 11:06

Make safety valve sizing strategies serializable

247901e

Merge pull request #252 from EvenSol/codex/fix-runtime-errors-in-tests

5a5685f

Make safety valve sizing strategies serializable

Fix corrosion allowance naming typo

eac070a

Merge pull request #253 from EvenSol/codex/fix-typo-in-method-name

84afe7d

Fix corrosion allowance naming typo

EvenSol added 4 commits November 1, 2025 11:38

Replace String.isBlank usage for Java 8 compatibility

9c763ad

Merge pull request #254 from EvenSol/codex/fix-compilation-errors-due…

df16e4d

…-to-isblank Fix Java 8 compatibility by avoiding String.isBlank

Fix Optional.orElseThrow usage in safety report test

d72ac67

Merge pull request #255 from EvenSol/codex/fix-compilation-errors-in-…

5d7bf5d

…processsafetyreportbuildertest

EvenSol merged commit 4e32fcb into equinor:master Nov 1, 2025
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Add process safety functionality#1614

Add process safety functionality#1614
EvenSol merged 25 commits intoequinor:masterfrom
EvenSol:master

EvenSol commented Nov 1, 2025

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	double refStdVolume = inStream.getFlowRate("Sm3/sec");
	double refStdVolume = (inStream != null) ? inStream.getFlowRate("Sm3/sec") : 0.0;

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Pull Request Overview

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codecov-commenter commented Nov 1, 2025 •

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