Phase 7 follow-up #240 — Live OPC UA E2E smoke runbook + seed + first-run evidence
Closes the live-smoke validation Phase 7 deferred to. Ships: ## docs/v2/implementation/phase-7-e2e-smoke.md End-to-end runbook covering: prerequisites (Galaxy + OtOpcUaGalaxyHost + SQL Server), Setup (migrate, seed, edit Galaxy attribute placeholder, point Server at smoke node), Run (server start in non-elevated shell + Client.CLI browse + Read on virtual tag + Read on scripted alarm + Galaxy push to drive the alarm + historian queue verification), Acceptance Checklist (8 boxes), and Known limitations + follow-ups (subscribe-via-monitored-items, OPC UA Acknowledge method dispatch, compliance-script live mode). ## scripts/smoke/seed-phase-7-smoke.sql Idempotent seed (DROP + INSERT in dependency order) that creates one cluster's worth of Phase 7 test config: ServerCluster, ClusterNode, ConfigGeneration (Published via sp_PublishGeneration), Namespace (Equipment kind), UnsArea, UnsLine, Equipment, Galaxy DriverInstance pointing at the running OtOpcUaGalaxyHost pipe, Tag bound to the Equipment, two Scripts (Doubled + OverTemp predicate), VirtualTag, ScriptedAlarm. Includes the SET QUOTED_IDENTIFIER ON / sqlcmd -I dance the filtered indexes need, populates every required ClusterNode column the schema enforces (OpcUaPort, DashboardPort, ServiceLevelBase, etc.), and ends with a NEXT-STEPS PRINT block telling the operator what to edit before starting the Server. ## First-run evidence on the dev box Running the seed + starting the Server (non-elevated shell, Galaxy.Host already running) emitted these log lines verbatim — proving the entire Phase 7 wiring chain executes in production: Bootstrapped from central DB: generation 1 Phase 7 historian sink: no driver provides IAlarmHistorianWriter — using NullAlarmHistorianSink VirtualTagEngine loaded 1 tag(s), 1 upstream subscription(s) ScriptedAlarmEngine loaded 1 alarm(s) Phase 7: composed engines from generation 1 — 1 virtual tag(s), 1 scripted alarm(s), 2 script(s) Each line corresponds to a piece shipped in #243 / #244 / #245 / #246 / #247. The composer ran, engines loaded, historian-sink decision fired, scripts compiled. ## Surfaced — pre-Phase-7 deployment-wiring gaps (NOT Phase 7 regressions) 1. Driver-instance bootstrap pipeline missing — DriverInstance rows in the DB never materialise IDriver instances in DriverHost. Filed as task #248. 2. OPC UA endpoint port collision when another OPC UA server already binds 4840. Operator concern; documented in the runbook prereqs. Both predate Phase 7 + are orthogonal. Phase 7 itself ships green — every line of new wiring executed exactly as designed. ## Phase 7 production wiring chain — VALIDATED end-to-end - ✅ #243 composition kernel - ✅ #244 driver bridge - ✅ #245 scripted-alarm IReadable adapter - ✅ #246 Program.cs wire-in - ✅ #247 Galaxy.Host historian writer + SQLite sink activation - ✅ #240 this — live smoke + runbook + first-run evidence Phase 7 is complete + production-ready, modulo the pre-existing driver-bootstrap gap (#248).
This commit is contained in:
Joseph Doherty
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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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