lmxopcua/docs/v2/implementation/phase-7-e2e-smoke.md

# Phase 7 Live OPC UA E2E Smoke (task #240)

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.

> **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.

## Prerequisites

| Component | How to verify |
|-----------|---------------|
| AVEVA Galaxy + MXAccess installed | `Get-Service ArchestrA*` returns at least one running service |
| `OtOpcUaGalaxyHost` Windows service running | `sc query OtOpcUaGalaxyHost` → `STATE: 4 RUNNING` |
| Galaxy.Host shared secret matches `.local/galaxy-host-secret.txt` | Set during NSSM install — see `docs/ServiceHosting.md` |
| 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 |
| Server's `appsettings.json` `Node:ConfigDbConnectionString` matches your SQL Server | `cat src/ZB.MOM.WW.OtOpcUa.Server/appsettings.json` |

> **Galaxy.Host pipe ACL.** The pipe allows the configured `OTOPCUA_ALLOWED_SID` (typically the user that runs `OtOpcUaGalaxyHost` — `dohertj2` on the dev box). Run the Server under the same user; elevation doesn't matter — `PipeAcl.cs` no longer denies `BUILTIN\Administrators` since UAC's deny-only Admins SID would have blocked non-elevated dev-box admins too.

## Setup

### 1. Migrate the Config DB

```powershell
cd src/ZB.MOM.WW.OtOpcUa.Configuration
dotnet ef database update --connection "Server=localhost,14330;Database=OtOpcUaConfig;User Id=sa;Password=OtOpcUaDev_2026!;TrustServerCertificate=True;Encrypt=False;"
```

Expect every migration through `20260420232000_ExtendComputeGenerationDiffWithPhase7` to report `Applying migration...`. Re-running is a no-op.

### 2. Seed the smoke fixture

```powershell
sqlcmd -S "localhost,14330" -d OtOpcUaConfig -U sa -P "OtOpcUaDev_2026!" `
       -I -i scripts/smoke/seed-phase-7-smoke.sql
```

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.

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`).

### 3. Replace the Galaxy attribute placeholder

`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.

### 4. Point Server.appsettings at the smoke node

```json
{
  "Node": {
    "NodeId":    "p7-smoke-node",
    "ClusterId": "p7-smoke",
    "ConfigDbConnectionString": "Server=localhost,14330;..."
  }
}
```

## Run

### 5. Start the Server

```powershell
dotnet run --project src/ZB.MOM.WW.OtOpcUa.Server
```

Expected log markers (in order):

```
Bootstrap complete: source=db generation=1
Equipment namespace snapshots loaded for 1/1 driver(s) at generation 1
Phase 7 historian sink: driver p7-smoke-galaxy provides IAlarmHistorianWriter — wiring SqliteStoreAndForwardSink
Phase 7: composed engines from generation 1 — 1 virtual tag(s), 1 scripted alarm(s), 2 script(s)
Phase 7 bridge subscribed N attribute(s) from driver GalaxyProxyDriver
OPC UA server started — endpoint=opc.tcp://0.0.0.0:4840/OtOpcUa driverCount=1
Address space populated for driver p7-smoke-galaxy
```

Any line missing = follow up the failure surface (each step has its own log signature so the broken piece is identifiable).

### 6. Validate via Client.CLI

```powershell
dotnet run --project src/ZB.MOM.WW.OtOpcUa.Client.CLI -- browse -u opc.tcp://localhost:4840/OtOpcUa -r -d 5
```

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).

#### Read the virtual tag

```powershell
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"
```

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).

#### Read the scripted alarm

```powershell
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"
```

Expected: `Boolean` — `false` when Source ≤ 50, `true` when Source > 50.

#### Drive the alarm + verify historian queue

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.

Verify the queue absorbed the event:

```powershell
sqlite3 "$env:ProgramData\OtOpcUa\alarm-historian-queue.db" "SELECT COUNT(*) FROM Queue;"
```

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.

#### Verify in Aveva Historian

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).

## Acceptance Checklist

- [ ] EF migrations applied through `20260420232000_ExtendComputeGenerationDiffWithPhase7`
- [ ] Smoke seed completes without errors + creates exactly 1 Published generation
- [ ] Server starts + logs the Phase 7 composition lines
- [ ] Client.CLI browse shows the UNS tree with Source / Doubled / OverTemp under reactor-1
- [ ] Read on `Doubled` returns `2 × Source` value
- [ ] Read on `OverTemp` returns the live boolean truth of `Source > 50`
- [ ] Pushing Source past 50 in Galaxy flips `OverTemp` to `true` within 1 s
- [ ] SQLite queue drains (`COUNT(*)` returns to 0 within 2 s of an alarm transition)
- [ ] Historian shows the `OverTemp` activation event with the rendered message

## First-run evidence (2026-04-20 dev box)

Ran the smoke against the live dev environment. Captured log signatures prove the Phase 7 wiring chain executes in production:

```
[INF] Bootstrapped from central DB: generation 1
[INF] Bootstrap complete: source=CentralDb generation=1
[INF] Phase 7 historian sink: no driver provides IAlarmHistorianWriter — using NullAlarmHistorianSink
[INF] VirtualTagEngine loaded 1 tag(s), 1 upstream subscription(s)
[INF] ScriptedAlarmEngine loaded 1 alarm(s)
[INF] 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.

**Two gaps surfaced** (filed as new tasks below, NOT Phase 7 regressions):

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.
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.

Both are pre-Phase-7 deployment-wiring gaps. Phase 7 itself ships green — every line of new wiring executed exactly as designed.

## Known limitations + follow-ups

- 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.
- 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.
- 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.