Validate DESIGN_MATRIX when running DESIGN2PARAMS

This commit makes us run validation for DESIGN_MATRIX when parsing
configs using DESIGN2PARAMS, and log a warning if it would have failed.

Author: jonathan-eq

src/ert/config/design_matrix.py

@@ -33,7 +33,7 @@ def __post_init__(self) -> None:
                 self.active_realizations,
                 self.design_matrix_df,
                 self.parameter_configuration,
-            ) = self.read_design_matrix()
+            ) = self.read_and_validate_design_matrix()
         except (ValueError, AttributeError) as exc:
             raise ConfigValidationError.with_context(
                 f"Error reading design matrix {self.xls_filename}: {exc}",
@@ -157,7 +157,7 @@ def merge_with_existing_parameters(
                 new_param_config += [parameter_group]
         return new_param_config, design_parameter_group
 
-    def read_design_matrix(
+    def read_and_validate_design_matrix(
         self,
     ) -> tuple[list[bool], pd.DataFrame, GenKwConfig]:
         # Read the parameter names (first row) as strings to prevent pandas from modifying them.

src/ert/config/ert_config.py

@@ -23,6 +23,7 @@
 from pydantic import field_validator
 from pydantic.dataclasses import dataclass, rebuild_dataclass
 
+from ert.config.design_matrix import DesignMatrix
 from ert.config.parsing.context_values import ContextBoolEncoder
 from ert.plugins import ErtPluginManager
 from ert.plugins.workflow_config import ErtScriptWorkflow
@@ -459,7 +460,7 @@ def create_list_of_forward_model_steps_to_run(
     env_pr_fm_step: dict[str, dict[str, Any]],
 ) -> list[ForwardModelStep]:
     errors = []
-    fm_steps = []
+    fm_steps: list[ForwardModelStep] = []
 
     env_vars = {}
     for key, val in config_dict.get("SETENV", []):
@@ -511,6 +512,12 @@ def create_list_of_forward_model_steps_to_run(
             fm_steps.append(fm_step)
 
     for fm_step in fm_steps:
+        if fm_step.name == "DESIGN2PARAMS":
+            xls_filename = fm_step.private_args.get("<xls_filename>")
+            designsheet = fm_step.private_args.get("<designsheet>")
+            defaultsheet = fm_step.private_args.get("<defaultssheet>")
+            validate_ert_design_matrix(xls_filename, designsheet, defaultsheet)
+
         if fm_step.name in preinstalled_forward_model_steps:
             try:
                 substituted_json = create_forward_model_json(
@@ -1253,5 +1260,14 @@ def _forward_model_step_from_config_file(
     )
 
 
+def validate_ert_design_matrix(xlsfilename, designsheetname, defaultssheetname):
+    try:
+        DesignMatrix(xlsfilename, designsheetname, defaultssheetname)
+    except ConfigValidationError as err:
+        logger.warning(
+            f"DESIGN_MATRIX validation of DESIGN2PARAMS would have failed with: {err!s}"
+        )
+
+
 # Due to circular dependency in type annotations between ErtConfig -> WorkflowJob -> ErtScript -> ErtConfig
 rebuild_dataclass(ErtConfig)

tests/ert/unit_tests/config/test_ert_config.py

@@ -10,6 +10,7 @@
 from textwrap import dedent
 from unittest.mock import MagicMock
 
+import pandas as pd
 import pytest
 from hypothesis import HealthCheck, assume, given, settings
 from hypothesis import strategies as st
@@ -29,6 +30,7 @@
 from ert.config.parsing.queue_system import QueueSystem
 from ert.plugins import ErtPluginManager
 from ert.shared import ert_share_path
+from tests.ert.ui_tests.cli.analysis.test_design_matrix import _create_design_matrix
 
 from .config_dict_generator import config_generators
 
@@ -1991,3 +1993,23 @@ def run(self, *args):
 
     assert ert_config.substitutions["<FOO>"] == "ertconfig_foo"
     assert ert_config.substitutions["<FOO2>"] == "ertconfig_foo2"
+
+
+def test_design2params_also_validates_design_matrix(tmp_path, caplog):
+    design_matrix_file = tmp_path / "my_design_matrix.xlsx"
+    _create_design_matrix(
+        design_matrix_file,
+        pd.DataFrame(
+            {
+                "REAL": [1],
+                "a": [1],
+                "category": ["cat1"],
+            }
+        ),
+        pd.DataFrame([["b", 1], ["c", 2]]),
+    )
+
+    ErtConfig.from_file_contents(
+        f"NUM_REALIZATIONS 1\nFORWARD_MODEL DESIGN2PARAMS(<xls_filename>={design_matrix_file}, <designsheet>=DesignSheet01,<defaultsheet>=DefaultSheet)"
+    )
+    assert "DESIGN_MATRIX validation of DESIGN2PARAMS" in caplog.text