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refactor(pinn): extract heat exchanger specifics to refs/
Moved heat-exchanger-specific content from pinn/SKILL.md to pinn/refs/heat_exchanger.md: complexity ladder table, known failure modes (U->0, counterflow signs), property mappings (REFPROP/PCHIP), multi-episode training. PINN skill is now domain-agnostic. pinn/SKILL.md reduced from 4961w to 4274w (~14%).
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# Heat Exchanger PINN Notes
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Project-specific notes for heat exchanger PINNs with phase change. Extracted from the general [PINN skill](../SKILL.md) to keep it domain-agnostic.
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---
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## Complexity ladder (heat exchanger example)
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| Level | Model | Assumptions | What it tests |
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| 0 | Persistence: y(t) = y(t-1) | None | Does model capture any dynamics? |
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| 1 | Exponential decay: T(t) = T_ss + (T_0 - T_ss) exp(-t/tau) | First-order response | Dominant thermal mode |
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| 2 | Linear state-space / DMDc: fit A, B via OLS on finite differences (or Dynamic Mode Decomposition with control) | Linear dynamics | Near-linear regime |
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| 3 | Pure data MLP (no physics loss) | NN can interpolate | If PINN doesn't beat this, physics constraint hurts |
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| 4 | Effectiveness-NTU closed form | 1D, constant Cp, steady state | Analytical sanity check |
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| 5 | 1D ODE with constant Cp (scipy solve_bvp) | 1D, constant Cp | Classical numerical baseline |
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| 6 | 1D ODE with enthalpy (scipy solve_bvp) | 1D, variable properties | Phase change handling |
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| 7 | 1D PINN with enthalpy | 1D, learned U | Differentiable model, parameter estimation |
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| 8 | 2D PINN with radial maldistribution | 2D, learned U + u_r | Full physics |
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---
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## Hard BC example (heat exchanger)
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For our heat exchanger: u_{r,tube}(z,r) = r(R-r) * NN(z,r) enforces zero radial velocity at r=0 and r=R by construction. Same principle as Sukumar & Srivastava 2022.
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---
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## Known failure modes
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**Degenerate U -> 0**: When learning a heat transfer coefficient U jointly with the network, the optimizer may find U -> 0 (no heat transfer, flat profiles). This satisfies the PDE trivially.
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- Fix: bound U in [100, 5000], initialize near a physically reasonable value (~500).
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- Fix: penalize |dT/dz| being too small (the network should predict temperature change).
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**Sign errors in counterflow**: The counterflow BVP in z-coordinates has both fluids' enthalpies decreasing in z:
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- dh_t/dz = -U*A'*(T_t - T_s)/m_dot_t (tube cools, < 0 since T_t > T_s)
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- dh_s/dz = -U*A'*(T_t - T_s)/m_dot_s (same sign! shell also decreases in z, but its flow is -z so it warms)
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The counterflow is encoded in BCs (h_t at z=0, h_s at z=L), not in opposing ODE signs.
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Common mistake: putting dh_s/dz = +q gives dh_s/dz > 0 (shell hot at z=0 exit, cold at z=L entry -- wrong).
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**NN vs scalar parameter**: When a scalar (U) and a NN (temperature field) are optimized jointly, the NN is easier to update (more parameters, more gradient signal). The scalar gets stuck. Fix: use different learning rates, or estimate U separately first.
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---
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## Property Mappings (EoS for PINNs)
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For heat exchangers with phase change, the T(h) mapping from REFPROP/GERG-2008 must be made differentiable.
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**Recipe:**
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1. Generate REFPROP data: T vs h at constant P, dense enough near the phase boundary (~200 points over T = [100, 300] K).
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2. Fit a cubic spline to get ~20 minimal knots (reject redundant knots where the curve is nearly linear).
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3. Build PCHIP on those knots for monotonicity guarantee (cubic spline can wiggle; PCHIP cannot).
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4. Wrap for PyTorch autograd:
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```python
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class PchipFunction(torch.autograd.Function):
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@staticmethod
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def forward(ctx, h):
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T = pchip_interp(h.detach().numpy()) # scipy
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ctx.save_for_backward(h)
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return torch.tensor(T, dtype=h.dtype, device=h.device)
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@staticmethod
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def backward(ctx, grad_output):
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h, = ctx.saved_tensors
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dTdh = pchip_interp.derivative()(h.detach().cpu().numpy()) # scipy
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return grad_output * torch.tensor(dTdh, dtype=h.dtype, device=h.device)
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```
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5. Use float64 throughout. float32 loses precision near the phase boundary where dT/dh is small.
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**Why h -> T and not T -> h?** The h(T) direction has a steep region near phase change where dh/dT = Cp -> infinity. The inverse T(h) is smooth and monotone everywhere. Always solve in h space, convert to T only for losses and visualization.
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---
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## Initial Conditions and Multi-Episode Training
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IC is a loss term, but in practice ICs from real plant data are noisy and uncertain.
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**Options (in order of complexity):**
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1. Hard-code IC from first observed data point. Simplest; biased if sensor lags.
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2. Learnable IC: optimize IC scalars jointly with the network. Adds ~n_states parameters. Works well with L-BFGS polish.
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3. Soft IC loss: penalize `||u(t=0) - u_obs(0)||^2` as one loss term. Lets optimizer trade off IC vs physics fit.
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**Multi-episode training** (e.g., ~10 cold restarts over a year):
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- Each episode needs its own IC.
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- Common pattern: learn per-episode IC vector `ic_k` while sharing the physics network across episodes.
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- Warm-start trick: if you have a pure-data pre-fit (Level 3 baseline), initialize PINN data-loss weights from that fit.
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---
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## Domain decomposition (heat exchanger note)
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Could split axially (cold end / hot end) if the solution has different character in different regions.
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---
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## Heat-exchanger-specific symptom table entries
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| Symptom | Likely cause |
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| Loss decreases then explodes | Numerical instability in T(h) near phase boundary |
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| Loss NaN | temperature outside EoS range |
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| U converges to 0 or bound | Degenerate solution, check sign convention |
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| PINN worse than pure-data MLP | Physics constraint fighting the data |
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