Validate DESIGN_MATRIX when running DESIGN2PARAMS

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", []):
@@ -510,7 +511,17 @@ def create_list_of_forward_model_steps_to_run(
         if should_add_step:
             fm_steps.append(fm_step)
 
+    design_matrices: list[DesignMatrix] = []
     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>")
+            if design_matrix := validate_ert_design_matrix(
+                xls_filename, designsheet, defaultsheet
+            ):
+                design_matrices.append(design_matrix)
+
         if fm_step.name in preinstalled_forward_model_steps:
             try:
                 substituted_json = create_forward_model_json(
@@ -539,6 +550,15 @@ def create_list_of_forward_model_steps_to_run(
                     f"Unexpected plugin forward model exception: {e!s}",
                     context=fm_step.name,
                 )
+    try:
+        main_design_matrix: DesignMatrix | None = None
+        for design_matrix in design_matrices:
+            if main_design_matrix is None:
+                main_design_matrix = design_matrix
+            else:
+                main_design_matrix = main_design_matrix.merge_with_other(design_matrix)
+    except Exception as exc:
+        logger.warning(f"Design matrix merging would have failed due to: {exc}")
 
     if errors:
         raise ConfigValidationError.from_collected(errors)
@@ -1253,5 +1273,16 @@ def _forward_model_step_from_config_file(
     )
 
 
+def validate_ert_design_matrix(
+    xlsfilename, designsheetname, defaultssheetname
+) -> DesignMatrix | None:
+    try:
+        return DesignMatrix(xlsfilename, designsheetname, defaultssheetname)
+    except Exception as exc:
+        logger.warning(
+            f"DESIGN_MATRIX validation of DESIGN2PARAMS would have failed with: {exc!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

@@ -10,13 +10,15 @@
 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
 from pydantic import RootModel, TypeAdapter
 
 from ert.config import ConfigValidationError, ErtConfig, HookRuntime
 from ert.config.ert_config import _split_string_into_sections, create_forward_model_json
+from ert.config.forward_model_step import ForwardModelStep
 from ert.config.parsing import ConfigKeys, ConfigWarning
 from ert.config.parsing.context_values import (
     ContextBool,
@@ -29,6 +31,7 @@
 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 +1994,75 @@ 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, monkeypatch):
+    design_matrix_file = tmp_path / "my_design_matrix.xlsx"
+    _create_design_matrix(
+        design_matrix_file,
+        pd.DataFrame(
+            {
+                "REAL": ["not_a_valid_real"],
+                "a": [1],
+                "category": ["cat1"],
+            }
+        ),
+        pd.DataFrame([["b", 1], ["c", 2]]),
+    )
+    mock_design2params = ForwardModelStep(
+        "DESIGN2PARAMS",
+        "/usr/bin/env",
+        arglist=["<IENS>", "<xls_filename>", "<designsheet>", "<defaultssheet>"],
+    )
+    monkeypatch.setattr(
+        ErtConfig,
+        "PREINSTALLED_FORWARD_MODEL_STEPS",
+        {"DESIGN2PARAMS": mock_design2params},
+    )
+    ErtConfig.from_file_contents(
+        f"NUM_REALIZATIONS 1\nFORWARD_MODEL DESIGN2PARAMS(<xls_filename>={design_matrix_file}, <designsheet>=DesignSheet01,<defaultssheet>=DefaultSheet)"
+    )
+    assert "DESIGN_MATRIX validation of DESIGN2PARAMS" in caplog.text
+
+
+def test_multiple_design2params_also_validates_design_matrix_merging(
+    tmp_path, caplog, monkeypatch
+):
+    design_matrix_file = tmp_path / "my_design_matrix.xlsx"
+    design_matrix_file2 = tmp_path / "my_design_matrix2.xlsx"
+    _create_design_matrix(
+        design_matrix_file,
+        pd.DataFrame(
+            {
+                "REAL": [0, 1],
+                "letters": ["x", "y"],
+            }
+        ),
+        pd.DataFrame([["a", 1], ["c", 2]]),
+    )
+    _create_design_matrix(
+        design_matrix_file2,
+        pd.DataFrame({"REAL": [1, 2], "numbers": [99, 98]}),
+        pd.DataFrame(),
+    )
+    mock_design2params = ForwardModelStep(
+        "DESIGN2PARAMS",
+        "/usr/bin/env",
+        arglist=["<IENS>", "<xls_filename>", "<designsheet>", "<defaultssheet>"],
+    )
+    monkeypatch.setattr(
+        ErtConfig,
+        "PREINSTALLED_FORWARD_MODEL_STEPS",
+        {"DESIGN2PARAMS": mock_design2params},
+    )
+    ErtConfig.from_file_contents(
+        f"""\
+            NUM_REALIZATIONS 1
+            FORWARD_MODEL DESIGN2PARAMS(<xls_filename>={design_matrix_file}, <designsheet>=DesignSheet01,<defaultssheet>=DefaultSheet)
+            FORWARD_MODEL DESIGN2PARAMS(<xls_filename>={design_matrix_file2}, <designsheet>=DesignSheet01,<defaultssheet>=DefaultSheet)
+            """
+    )
+    assert (
+        "Design matrix merging would have failed due to: Design Matrices don't have the same active realizations"
+        in caplog.text
+    )