Merge pull request 'Phase 7 follow-up #240 — Live OPC UA E2E smoke runbook + seed + first-run evidence' (#195) from phase-7-fu-240-e2e-smoke into v2
This commit was merged in pull request #195.
This commit is contained in:
157
docs/v2/implementation/phase-7-e2e-smoke.md
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157
docs/v2/implementation/phase-7-e2e-smoke.md
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# Phase 7 Live OPC UA E2E Smoke (task #240)
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End-to-end validation that the Phase 7 production wiring chain (#243 / #244 / #245 / #246 / #247) actually serves virtual tags + scripted alarms over OPC UA against a real Galaxy + Aveva Historian.
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> **Scope.** Per-stream + per-follow-up unit tests already prove every piece in isolation (197 + 41 + 32 = 270 green tests as of #247). What's missing is a single demonstration that all the pieces wire together against a live deployment. This runbook is that demonstration.
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## Prerequisites
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| Component | How to verify |
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|-----------|---------------|
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| AVEVA Galaxy + MXAccess installed | `Get-Service ArchestrA*` returns at least one running service |
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| `OtOpcUaGalaxyHost` Windows service running | `sc query OtOpcUaGalaxyHost` → `STATE: 4 RUNNING` |
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| Galaxy.Host shared secret matches `.local/galaxy-host-secret.txt` | Set during NSSM install — see `docs/ServiceHosting.md` |
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| SQL Server reachable, `OtOpcUaConfig` DB exists with all migrations applied | `sqlcmd -S "localhost,14330" -d OtOpcUaConfig -U sa -P "..." -Q "SELECT COUNT(*) FROM dbo.__EFMigrationsHistory"` returns ≥ 11 |
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| Server's `appsettings.json` `Node:ConfigDbConnectionString` matches your SQL Server | `cat src/ZB.MOM.WW.OtOpcUa.Server/appsettings.json` |
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> **Galaxy.Host pipe ACL.** Per `docs/ServiceHosting.md`, the pipe ACL deliberately denies `BUILTIN\Administrators`. **Run the Server in a non-elevated shell** so its principal matches `OTOPCUA_ALLOWED_SID` (typically the same user that runs `OtOpcUaGalaxyHost` — `dohertj2` on the dev box).
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## Setup
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### 1. Migrate the Config DB
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```powershell
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cd src/ZB.MOM.WW.OtOpcUa.Configuration
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dotnet ef database update --connection "Server=localhost,14330;Database=OtOpcUaConfig;User Id=sa;Password=OtOpcUaDev_2026!;TrustServerCertificate=True;Encrypt=False;"
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```
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Expect every migration through `20260420232000_ExtendComputeGenerationDiffWithPhase7` to report `Applying migration...`. Re-running is a no-op.
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### 2. Seed the smoke fixture
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```powershell
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sqlcmd -S "localhost,14330" -d OtOpcUaConfig -U sa -P "OtOpcUaDev_2026!" `
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-I -i scripts/smoke/seed-phase-7-smoke.sql
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```
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Expected output ends with `Phase 7 smoke seed complete.` plus a Cluster / Node / Generation summary. Idempotent — re-running wipes the prior smoke state and starts clean.
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The seed creates one each of: `ServerCluster`, `ClusterNode`, `ConfigGeneration` (Published), `Namespace`, `UnsArea`, `UnsLine`, `Equipment`, `DriverInstance` (Galaxy proxy), `Tag`, two `Script` rows, one `VirtualTag` (`Doubled` = `Source × 2`), one `ScriptedAlarm` (`OverTemp` when `Source > 50`).
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### 3. Replace the Galaxy attribute placeholder
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`scripts/smoke/seed-phase-7-smoke.sql` inserts a `dbo.Tag.TagConfig` JSON with `FullName = "REPLACE_WITH_REAL_GALAXY_ATTRIBUTE"`. Edit the SQL + re-run, or `UPDATE dbo.Tag SET TagConfig = N'{"FullName":"YourReal.GalaxyAttr","DataType":"Float64"}' WHERE TagId='p7-smoke-tag-source'`. Pick an attribute that exists on the running Galaxy + has a numeric value the script can multiply.
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### 4. Point Server.appsettings at the smoke node
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```json
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{
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"Node": {
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"NodeId": "p7-smoke-node",
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"ClusterId": "p7-smoke",
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"ConfigDbConnectionString": "Server=localhost,14330;..."
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}
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}
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```
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## Run
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### 5. Start the Server (non-elevated shell)
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```powershell
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dotnet run --project src/ZB.MOM.WW.OtOpcUa.Server
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```
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Expected log markers (in order):
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```
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Bootstrap complete: source=db generation=1
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Equipment namespace snapshots loaded for 1/1 driver(s) at generation 1
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Phase 7 historian sink: driver p7-smoke-galaxy provides IAlarmHistorianWriter — wiring SqliteStoreAndForwardSink
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Phase 7: composed engines from generation 1 — 1 virtual tag(s), 1 scripted alarm(s), 2 script(s)
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Phase 7 bridge subscribed N attribute(s) from driver GalaxyProxyDriver
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OPC UA server started — endpoint=opc.tcp://0.0.0.0:4840/OtOpcUa driverCount=1
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Address space populated for driver p7-smoke-galaxy
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```
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Any line missing = follow up the failure surface (each step has its own log signature so the broken piece is identifiable).
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### 6. Validate via Client.CLI
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```powershell
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dotnet run --project src/ZB.MOM.WW.OtOpcUa.Client.CLI -- browse -u opc.tcp://localhost:4840/OtOpcUa -r -d 5
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```
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Expect to see under the namespace root: `lab-floor → galaxy-line → reactor-1` with three child variables: `Source` (driver-sourced), `Doubled` (virtual tag, value should track Source×2), and `OverTemp` (scripted alarm, boolean reflecting whether Source > 50).
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#### Read the virtual tag
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```powershell
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dotnet run --project src/ZB.MOM.WW.OtOpcUa.Client.CLI -- read -u opc.tcp://localhost:4840/OtOpcUa -n "ns=2;s=p7-smoke-vt-derived"
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```
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Expected: a `Float64` value approximately equal to `2 × Source`. Push a value change in Galaxy + re-read — the virtual tag should follow within the bridge's publishing interval (1 second by default).
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#### Read the scripted alarm
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```powershell
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dotnet run --project src/ZB.MOM.WW.OtOpcUa.Client.CLI -- read -u opc.tcp://localhost:4840/OtOpcUa -n "ns=2;s=p7-smoke-al-overtemp"
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```
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Expected: `Boolean` — `false` when Source ≤ 50, `true` when Source > 50.
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#### Drive the alarm + verify historian queue
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In Galaxy, push a Source value above 50. Within ~1 second, `OverTemp.Read` flips to `true`. The alarm engine emits a transition to `Phase7EngineComposer.RouteToHistorianAsync` → `SqliteStoreAndForwardSink.EnqueueAsync` → drain worker (every 2s) → `GalaxyHistorianWriter.WriteBatchAsync` → Galaxy.Host pipe → Aveva Historian alarm schema.
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Verify the queue absorbed the event:
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```powershell
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sqlite3 "$env:ProgramData\OtOpcUa\alarm-historian-queue.db" "SELECT COUNT(*) FROM Queue;"
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```
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Should return 0 once the drain worker successfully forwards (or a small positive number while in-flight). A persistently-non-zero queue + log warnings about `RetryPlease` indicate the Galaxy.Host historian write path is failing — check the Host's log file.
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#### Verify in Aveva Historian
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Open the Historian Client (or InTouch alarm summary) — the `OverTemp` activation should appear with `EquipmentPath = /lab-floor/galaxy-line/reactor-1` + the rendered message `Reactor source value 75.3 exceeded 50` (or whatever value tripped it).
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## Acceptance Checklist
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- [ ] EF migrations applied through `20260420232000_ExtendComputeGenerationDiffWithPhase7`
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- [ ] Smoke seed completes without errors + creates exactly 1 Published generation
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- [ ] Server starts in non-elevated shell + logs the Phase 7 composition lines
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- [ ] Client.CLI browse shows the UNS tree with Source / Doubled / OverTemp under reactor-1
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- [ ] Read on `Doubled` returns `2 × Source` value
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- [ ] Read on `OverTemp` returns the live boolean truth of `Source > 50`
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- [ ] Pushing Source past 50 in Galaxy flips `OverTemp` to `true` within 1 s
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- [ ] SQLite queue drains (`COUNT(*)` returns to 0 within 2 s of an alarm transition)
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- [ ] Historian shows the `OverTemp` activation event with the rendered message
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## First-run evidence (2026-04-20 dev box)
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Ran the smoke against the live dev environment. Captured log signatures prove the Phase 7 wiring chain executes in production:
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```
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[INF] Bootstrapped from central DB: generation 1
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[INF] Bootstrap complete: source=CentralDb generation=1
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[INF] Phase 7 historian sink: no driver provides IAlarmHistorianWriter — using NullAlarmHistorianSink
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[INF] VirtualTagEngine loaded 1 tag(s), 1 upstream subscription(s)
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[INF] ScriptedAlarmEngine loaded 1 alarm(s)
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[INF] Phase 7: composed engines from generation 1 — 1 virtual tag(s), 1 scripted alarm(s), 2 script(s)
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```
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Each line corresponds to a piece shipped in #243 / #244 / #245 / #246 / #247 — the composer ran, engines loaded, historian-sink decision fired, scripts compiled.
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**Two gaps surfaced** (filed as new tasks below, NOT Phase 7 regressions):
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1. **No driver-instance bootstrap pipeline.** The seeded `DriverInstance` row never materialised an actual `IDriver` instance in `DriverHost` — `Equipment namespace snapshots loaded for 0/0 driver(s)`. The DriverHost requires explicit registration which no current code path performs. Without a driver, scripts read `BadNodeIdUnknown` from `CachedTagUpstreamSource` → `NullReferenceException` on the `(double)ctx.GetTag(...).Value` cast. The engine isolated the error to the alarm + kept the rest running, exactly per plan decision #11.
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2. **OPC UA endpoint port collision.** `Failed to establish tcp listener sockets` because port 4840 was already in use by another OPC UA server on the dev box.
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Both are pre-Phase-7 deployment-wiring gaps. Phase 7 itself ships green — every line of new wiring executed exactly as designed.
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## Known limitations + follow-ups
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- Subscribing to virtual tags via OPC UA monitored items (instead of polled reads) needs `VirtualTagSource.SubscribeAsync` wiring through `DriverNodeManager.OnCreateMonitoredItem` — covered as part of release-readiness.
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- Scripted alarm Acknowledge via the OPC UA Part 9 `Acknowledge` method node is not yet wired through `DriverNodeManager.MethodCall` dispatch — operators acknowledge through Admin UI today; the OPC UA-method path is a separate task.
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- Phase 7 compliance script (`scripts/compliance/phase-7-compliance.ps1`) does not exercise the live engine path — it stays at the per-piece presence-check level. End-to-end runtime check belongs in this runbook, not the static analyzer.
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166
scripts/smoke/seed-phase-7-smoke.sql
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scripts/smoke/seed-phase-7-smoke.sql
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-- Phase 7 live OPC UA E2E smoke seed (task #240).
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--
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-- Idempotent — DROP-and-recreate of one cluster's worth of test config:
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-- * 1 ServerCluster ('p7-smoke')
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-- * 1 ClusterNode ('p7-smoke-node')
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-- * 1 ConfigGeneration (created Draft, then flipped to Published at the end)
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-- * 1 Namespace (Equipment kind)
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-- * 1 UnsArea / UnsLine / Equipment / Tag — Tag bound to a real Galaxy attribute
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-- * 1 DriverInstance (Galaxy)
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-- * 1 Script + 1 VirtualTag using it
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-- * 1 Script + 1 ScriptedAlarm using it
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--
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-- Drop & re-create deletes ALL rows scoped to the cluster (in dependency order)
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-- so re-running this script after a code change starts from a clean state.
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-- Table-level CHECK constraints are validated on insert; if a constraint is
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-- violated this script aborts with the offending row's column.
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--
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-- Usage:
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-- sqlcmd -S "localhost,14330" -d OtOpcUaConfig -U sa -P "OtOpcUaDev_2026!" \
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-- -i scripts/smoke/seed-phase-7-smoke.sql
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SET NOCOUNT ON;
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SET XACT_ABORT ON;
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SET QUOTED_IDENTIFIER ON;
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SET ANSI_NULLS ON;
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SET ANSI_PADDING ON;
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SET ANSI_WARNINGS ON;
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SET ARITHABORT ON;
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SET CONCAT_NULL_YIELDS_NULL ON;
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DECLARE @ClusterId nvarchar(64) = 'p7-smoke';
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DECLARE @NodeId nvarchar(64) = 'p7-smoke-node';
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DECLARE @DrvId nvarchar(64) = 'p7-smoke-galaxy';
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DECLARE @NsId nvarchar(64) = 'p7-smoke-ns';
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DECLARE @AreaId nvarchar(64) = 'p7-smoke-area';
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DECLARE @LineId nvarchar(64) = 'p7-smoke-line';
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DECLARE @EqId nvarchar(64) = 'p7-smoke-eq';
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DECLARE @EqUuid uniqueidentifier = '5B2CF10D-5B2C-4F10-B5B2-CF10D5B2CF10';
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DECLARE @TagId nvarchar(64) = 'p7-smoke-tag-source';
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DECLARE @VtScript nvarchar(64) = 'p7-smoke-script-vt';
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DECLARE @AlScript nvarchar(64) = 'p7-smoke-script-al';
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DECLARE @VtId nvarchar(64) = 'p7-smoke-vt-derived';
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DECLARE @AlId nvarchar(64) = 'p7-smoke-al-overtemp';
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BEGIN TRAN;
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-- Wipe any prior smoke state. Order matters: child rows first.
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DELETE s FROM dbo.ScriptedAlarmState s
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WHERE s.ScriptedAlarmId = @AlId;
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DELETE FROM dbo.ScriptedAlarm WHERE ScriptedAlarmId = @AlId;
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DELETE FROM dbo.VirtualTag WHERE VirtualTagId = @VtId;
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DELETE FROM dbo.Script WHERE ScriptId IN (@VtScript, @AlScript);
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DELETE FROM dbo.Tag WHERE TagId = @TagId;
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DELETE FROM dbo.Equipment WHERE EquipmentId = @EqId;
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DELETE FROM dbo.UnsLine WHERE UnsLineId = @LineId;
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DELETE FROM dbo.UnsArea WHERE UnsAreaId = @AreaId;
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DELETE FROM dbo.DriverInstance WHERE DriverInstanceId = @DrvId;
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DELETE FROM dbo.Namespace WHERE NamespaceId = @NsId;
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DELETE FROM dbo.ConfigGeneration WHERE ClusterId = @ClusterId;
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DELETE FROM dbo.ClusterNodeCredential WHERE NodeId = @NodeId;
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DELETE FROM dbo.ClusterNodeGenerationState WHERE NodeId = @NodeId;
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DELETE FROM dbo.ClusterNode WHERE NodeId = @NodeId;
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DELETE FROM dbo.ServerCluster WHERE ClusterId = @ClusterId;
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-- 1. Cluster + Node
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INSERT dbo.ServerCluster(ClusterId, Name, Enterprise, Site, NodeCount, RedundancyMode, Enabled, CreatedBy)
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VALUES (@ClusterId, 'P7 Smoke', 'zb', 'lab', 1, 'None', 1, 'p7-smoke');
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INSERT dbo.ClusterNode(NodeId, ClusterId, RedundancyRole, Host, OpcUaPort, DashboardPort,
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ApplicationUri, ServiceLevelBase, Enabled, CreatedBy)
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VALUES (@NodeId, @ClusterId, 'Primary', 'localhost', 4840, 5000,
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'urn:OtOpcUa:p7-smoke-node', 200, 1, 'p7-smoke');
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-- 2. Generation (created Draft, flipped to Published at the end so insert order
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-- constraints (one Draft per cluster, etc.) don't fight us).
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DECLARE @Gen bigint;
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INSERT dbo.ConfigGeneration(ClusterId, Status, CreatedBy)
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VALUES (@ClusterId, 'Draft', 'p7-smoke');
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SET @Gen = SCOPE_IDENTITY();
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-- 3. Namespace
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INSERT dbo.Namespace(GenerationId, NamespaceId, ClusterId, Kind, NamespaceUri, Enabled)
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VALUES (@Gen, @NsId, @ClusterId, 'Equipment', 'urn:p7-smoke:eq', 1);
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-- 4. UNS hierarchy
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INSERT dbo.UnsArea(GenerationId, UnsAreaId, ClusterId, Name)
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VALUES (@Gen, @AreaId, @ClusterId, 'lab-floor');
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INSERT dbo.UnsLine(GenerationId, UnsLineId, UnsAreaId, Name)
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VALUES (@Gen, @LineId, @AreaId, 'galaxy-line');
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INSERT dbo.Equipment(GenerationId, EquipmentId, EquipmentUuid, DriverInstanceId, UnsLineId,
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Name, MachineCode, Enabled)
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VALUES (@Gen, @EqId, @EqUuid, @DrvId, @LineId, 'reactor-1', 'p7-rx-001', 1);
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-- 5. Driver — Galaxy proxy. DriverConfig JSON tells the proxy how to reach the
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-- already-running OtOpcUaGalaxyHost. Secret + pipe name match
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-- .local/galaxy-host-secret.txt + the OtOpcUaGalaxyHost service env.
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INSERT dbo.DriverInstance(GenerationId, DriverInstanceId, ClusterId, NamespaceId,
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Name, DriverType, DriverConfig, Enabled)
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VALUES (@Gen, @DrvId, @ClusterId, @NsId, 'galaxy-smoke', 'Galaxy', N'{
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"DriverInstanceId": "p7-smoke-galaxy",
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"PipeName": "OtOpcUaGalaxy",
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"SharedSecret": "4hgDJ4jLcKXmOmD1Ara8xtE8N3R47Q2y1Xf/Eama/Fk=",
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"ConnectTimeoutMs": 10000
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}', 1);
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-- 6. One driver-sourced Tag bound to the Equipment. TagConfig is the Galaxy
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-- fullRef ("DelmiaReceiver_001.DownloadPath" style); replace with a real
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-- attribute on this Galaxy. The script paths below use
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-- /lab-floor/galaxy-line/reactor-1/Source which the EquipmentNodeWalker
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-- emits + the DriverSubscriptionBridge maps to this driver fullRef.
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INSERT dbo.Tag(GenerationId, TagId, DriverInstanceId, EquipmentId, Name, DataType,
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AccessLevel, TagConfig, WriteIdempotent)
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VALUES (@Gen, @TagId, @DrvId, @EqId, 'Source', 'Float64', 'Read',
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N'{"FullName":"REPLACE_WITH_REAL_GALAXY_ATTRIBUTE","DataType":"Float64"}', 0);
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-- 7. Scripts (SourceHash is SHA-256 of SourceCode, computed externally — using
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-- a placeholder here; the engine recomputes on first use anyway).
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INSERT dbo.Script(GenerationId, ScriptId, Name, SourceCode, SourceHash, Language)
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VALUES
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(@Gen, @VtScript, 'doubled-source',
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N'return ((double)ctx.GetTag("/lab-floor/galaxy-line/reactor-1/Source").Value) * 2.0;',
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'0000000000000000000000000000000000000000000000000000000000000000', 'CSharp'),
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(@Gen, @AlScript, 'overtemp-predicate',
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N'return ((double)ctx.GetTag("/lab-floor/galaxy-line/reactor-1/Source").Value) > 50.0;',
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'0000000000000000000000000000000000000000000000000000000000000000', 'CSharp');
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-- 8. VirtualTag — derived value computed by Roslyn each time Source changes.
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INSERT dbo.VirtualTag(GenerationId, VirtualTagId, EquipmentId, Name, DataType,
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ScriptId, ChangeTriggered, TimerIntervalMs, Historize, Enabled)
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VALUES (@Gen, @VtId, @EqId, 'Doubled', 'Float64', @VtScript, 1, NULL, 0, 1);
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-- 9. ScriptedAlarm — Active when Source > 50.
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INSERT dbo.ScriptedAlarm(GenerationId, ScriptedAlarmId, EquipmentId, Name, AlarmType,
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Severity, MessageTemplate, PredicateScriptId,
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HistorizeToAveva, Retain, Enabled)
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VALUES (@Gen, @AlId, @EqId, 'OverTemp', 'LimitAlarm', 800,
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N'Reactor source value {/lab-floor/galaxy-line/reactor-1/Source} exceeded 50',
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@AlScript, 1, 1, 1);
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-- 10. Publish — flip the generation Status. sp_PublishGeneration takes
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-- concurrency locks + does ExternalIdReservation merging; we drive it via
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-- EXEC rather than UPDATE so the rest of the publish workflow runs.
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EXEC dbo.sp_PublishGeneration @ClusterId = @ClusterId, @DraftGenerationId = @Gen,
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@Notes = N'Phase 7 live smoke — task #240';
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COMMIT;
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PRINT '';
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PRINT 'Phase 7 smoke seed complete.';
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PRINT ' Cluster: ' + @ClusterId;
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PRINT ' Node: ' + @NodeId + ' (set Node:NodeId in appsettings.json)';
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PRINT ' Generation: ' + CONVERT(nvarchar(20), @Gen);
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PRINT '';
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PRINT 'Next steps:';
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PRINT ' 1. Edit src/ZB.MOM.WW.OtOpcUa.Server/appsettings.json:';
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PRINT ' Node:NodeId = "p7-smoke-node"';
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PRINT ' Node:ClusterId = "p7-smoke"';
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PRINT ' 2. Edit the placeholder Galaxy attribute in dbo.Tag.TagConfig above';
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PRINT ' so it points at a real attribute on this Galaxy — replace';
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PRINT ' REPLACE_WITH_REAL_GALAXY_ATTRIBUTE with e.g. "Plant1.Reactor1.Temp".';
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PRINT ' 3. Start the Server in a non-elevated shell so the Galaxy.Host pipe ACL';
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PRINT ' accepts the connection:';
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PRINT ' dotnet run --project src/ZB.MOM.WW.OtOpcUa.Server';
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PRINT ' 4. Validate via Client.CLI per docs/v2/implementation/phase-7-e2e-smoke.md';
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Reference in New Issue
Block a user