CFD Online Discussion Forums - [Other] Problem: Uncovered Faces

Hello everyone,

i got an error during solving due to uncovered Faces.

Here is my log-file:

..............
Reading field p
Reading field U
Reading/calculating face flux field phi
Initializing the GGI interpolator between master/shadow patches: DT-TO-RU-SIDE-1/DT-TO-RU-SIDE-2
Initializing the GGI interpolator between master/shadow patches: RU-TO-SVWG-SIDE-1/RU-TO-SVWG-SIDE-2
Initializing the GGI interpolator between master/shadow patches: SVWG-TO-SC-SIDE-2/SVWG-TO-SC-SIDE-1
From function void GGIInterpolation<MasterPatch, SlavePatch>::rescaleWeightingFactors() const
in file /home/lenama/OpenFOAM/OpenFOAM-1.6-ext/src/OpenFOAM/lnInclude/GGIInterpolationWeights.C at line 535
Uncovered faces found. On master: 0 on slave: 56

--> FOAM FATAL ERROR:
Found uncovered faces for GGI interface SVWG-TO-SC-SIDE-2/SVWG-TO-SC-SIDE-1 while the bridgeOverlap option is not set in the boundary file.
This is an unrecoverable error. Aborting.
From function void ggiPolyPatch::calcPatchToPatch() const
in file meshes/polyMesh/polyPatches/constraint/ggi/ggiPolyPatch.C at line 129.
FOAM aborting

The error occurs on a static GGI between stay-vane and spiral casing of my pumpturbine.

This is my checkMesh-log:

/*---------------------------------------------------------------------------*\
| ========= | |
| \\ / F ield | OpenFOAM Extend Project: Open source CFD |
| \\ / O peration | Version: 1.6-ext |
| \\ / A nd | Web: www.extend-project.de |
| \\/ M anipulation | |
\*---------------------------------------------------------------------------*/
Build : 1.6-ext
Exec : checkMesh
Date : Apr 14 2011
Time : 17:25:04
Host : hdhhteris
PID : 26239
Case : /home/lenama/OpenFOAM/lenama-1.6-ext/run/PT-70/Steady/scsvwgrudt/p04_steady
nProcs : 1
SigFpe : Enabling floating point exception trapping (FOAM_SIGFPE).
// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //
Create time
Create polyMesh for time = 0
Time = 0
Mesh stats
points: 20932365
faces: 61290393
internal faces: 59796813
cells: 20181201
boundary patches: 17
point zones: 0
face zones: 10
cell zones: 1
Overall number of cells of each type:
hexahedra: 20181201
prisms: 0
wedges: 0
pyramids: 0
tet wedges: 0
tetrahedra: 0
polyhedra: 0
Checking topology...
Boundary definition OK.
Point usage OK.
Upper triangular ordering OK.
Face vertices OK.
*Number of regions: 5
The mesh has multiple regions which are not connected by any face.
<<Writing region information to "0/cellToRegion"
Checking patch topology for multiply connected surfaces ...
Patch Faces Points Surface topology
DT-TO-RU-SIDE-1 6720 6817 ok (non-closed singly connected)
INFLOW 8620 8742 ok (non-closed singly connected)
WALLSTAT-DT 60370 60585 ok (non-closed singly connected)
DT-TO-RU-SIDE-2 37665 37909 ok (non-closed singly connected)
RU-TO-SVWG-SIDE-1 27216 27702 ok (non-closed singly connected)
WALLROT-RU 222921 223633 ok (non-closed singly connected)
WALLSTAT-RU 28674 30132 ok (non-closed singly connected)
OUTFLOW 5126 5240 ok (non-closed singly connected)
SVWG-TO-SC-SIDE-2 17600 18003 ok (non-closed singly connected)
WALLSTAT-SC 75666 76181 ok (non-closed singly connected)
NOSE_LOWER-SIDE-1 11760 12027 ok (non-closed singly connected)
NOSE_LOWER-SIDE-2 11760 12027 ok (non-closed singly connected)
NOSE_UPPER-SIDE-1 11760 12027 ok (non-closed singly connected)
NOSE_UPPER-SIDE-2 12096 12369 ok (non-closed singly connected)
RU-TO-SVWG-SIDE-2 53872 54948 ok (non-closed singly connected)
SVWG-TO-SC-SIDE-1 68432 69825 ok (non-closed singly connected)
WALLSTAT-SVWG 833322 836325 ok (non-closed singly connected)
Checking geometry...
This is a 3-D mesh
Overall domain bounding box (-0.551782 -0.722608 -1.13494) (2.40857 0.611412 0.21191)
Mesh (non-empty, non-wedge) directions (1 1 1)
Mesh (non-empty) directions (1 1 1)
Mesh (non-empty, non-wedge) dimensions 3
Boundary openness (2.09114e-16 2.47771e-16 6.42884e-17) Threshold = 1e-06 OK.
Max cell openness = 1.14105e-14 OK.
Max aspect ratio = 285.062 OK.
Minumum face area = 1.98427e-09. Maximum face area = 0.000732129. Face area magnitudes OK.
Min volume = 3.78415e-13. Max volume = 6.52634e-06. Total volume = 1.18127. Cell volumes OK.
Mesh non-orthogonality Max: 79.7603 average: 22.3968 Threshold = 70
*Number of severely non-orthogonal faces: 226963.
Non-orthogonality check OK.
Writing 226963 non-orthogonal faces to set nonOrthoFaces
Face pyramids OK.
***Max skewness = 5.39191, 399 highly skew faces detected which may impair the quality of the results Threshold = 4
Writing 399 skew faces to set skewFaces
Failed 1 mesh checks.
End

There should be no uncovered faces in my mesh - so why does OF cause this error? How can I show this "uncovered faces" in ParaView or inhibit this problem?The mesh also passed the checkMesh in ICEM!
So does anyone have an idea or some experiences to resolve this error?

Thanks in advance.

Regards Markus