YAU.POC/yau-plant-assistant
2
0
Fork 0
Code Issues Pull requests Projects Releases Packages Wiki Activity Actions
yau-plant-assistant/REQUESTS.md
Claude 8aba1f7f5c Rebuild the stand-in historian on CI Server item names 
The three open Phase 5 findings were one defect: the stand-in was keyed on
CI Server POINT names (PS_STN_WET_WELL_LEVEL) when the historian is keyed on
CI Server ITEM names (AID.WRPS.STN.LEVEL). Modbus carries register numbers,
not names, so those two layers are free to differ - and do. Reconciling
against the register map, as planned, would only have proved the first three
namespaces agreed with each other.

Rebuilt from WRPS/05-scada/modbus, so item names, sample rates, retention and
timestamp semantics come from the machine rather than from a guess.

(a) Level tag does not join. PS_STN_WET_WELL_LEVEL becomes a tag row in its
    own right; LIT-101 is marked NOT HISTORISED - a field input on %IW0 that
    never reaches SCADA. It was the only seed row carrying two addresses.
    public.historian_items holds the item-to-tag mapping, generated by
    scripts/gen_historian_items.py and enforced non-empty at generate, at
    deploy and at verify.

(b) first_alarm/last_alarm returned UTC. Converted inside the measure, so it
    stays in Cube and happens once. Aggregate first, convert after - the other
    order picks the wrong row across a DST fall-back. Returned as a formatted
    string with a companion site_timezone measure. Storage being UTC is now
    confirmed, not assumed: all 49 points carry TIME_ZONE "Date+time GMT" and
    every history group CORRECT_DAYLIGHT=0. This answers Phase 4 task 4.

(c) High level alarm filed against the wrong equipment. Both sides were right
    about different things; the defect was asserting equipment twice. The
    history now carries no equipment column at all - faithful, since CI
    Server's section tree stops at the station and three pumps. Equipment is
    reached bit -> tag -> equipment via public.alarm_bits.

Alarms are derived, not stored: CI Server's ALARM_HISTORY group is empty
because every item imports with alarming off. Decomposing the alarm word needs
no configuration that does not exist.

Three things the SCADA config changed that were never filed as faults:
  - retention is 7 days, not 30. The advisory path was reporting a month of
    evidence drawn from a week of data
  - the analogue rate is 5 s, not 60. Two measures multiplied sample counts by
    a hardcoded 60 - a twelvefold overstatement that read as plausible
  - the deadband warning in process_values.yml was wrong and was steering
    people away from the correct measure

db/002_fixtures.sql now asserts its own counts at load and cross-checks the
alarm derivation against two independent signals. Those prove the pipeline,
not the plant.

db/README-standin-historian.md documents removal: the seam between generation
and contract, and twelve assumptions about imh that are NOT confirmed. Two of
them fail silently.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
2026-08-31 11:42:02 +10:00

13 KiB
Raw Blame History

Outstanding requests — WRPS Plant Assistant

One thing is still needed from other people, of the three originally raised. Nothing else is blocking: as at 28 August 2026 the assistant runs end to end on lin001 with a real model — the question box, name resolution, the data translator, document search, all four answer lanes, the rulebook, the working panel, the logbook and the document library are all live and were exercised by hand on the host.

Items 1 and 2 are both delivered and closed — they are kept below as a record of what was asked for and what arrived. What is still missing is real plant data. That is the request furthest outside this project's control, and it cannot be hurried at the end.

Item 3 needs the owner of the imh historian, who is not yet identified. Contact for items 1 and 2, both closed: Daniel Watson (daniel.watson@yokogawa.com).

# Request Needed for Blocks
1 Azure OpenAI account, 3 deployments The two AI steps — classifying the question, wording the answer Delivered 27 Aug 2026 — closed
2 Three public DNS records + DC pinpoint records Reaching the assistant by name from a control-room PC Delivered 27 Aug 2026 — closed
3 Read-only login to the imh historian Real plant figures instead of stand-ins Phases 4, 5; every data answer

1. Azure OpenAI account — DELIVERED

Closed 27 August 2026. The resource is live at yau-dem-oai.openai.azure.com, API version 2024-10-21, and lin001 reaches it outbound over HTTPS. NO_LLM_STUB=false on the host: both AI steps — classifying the question and wording the answer — run against the real model, and the documents were indexed with real embeddings the same day. Switching it on surfaced eight failures the stand-in had hidden; all eight are fixed and pinned by cases in eval/testset.jsonl, which grew from 67 to 75.

Two things are worth recording, and the second needs a decision.

  • The deployments as built are not the deployments as requested. The host runs CHAT_DEPLOYMENT=gpt-4o and CHEAP_DEPLOYMENT=gpt-4o — the same model on both lanes — with text-embedding-3-small for embeddings as asked. The request was for a GPT-5-mini-class model on the cheap lane specifically so that classification, entity extraction and tool selection would not bill at flagship rates.
  • The cost estimate below therefore no longer holds. ≈US$35/month at 3,000 questions was computed on three calls per question with two of them on a cheap model. With both chat lanes on gpt-4o, the same traffic bills materially higher. Either deploy a cheap-lane model and repoint CHEAP_DEPLOYMENT, or re-cost the budget ask before the demo period. The US$50 monthly budget alert should be confirmed as actually set, since it is now the thing that catches this rather than the estimate.

The original request follows, unchanged.

Action

Create an Azure OpenAI resource in the existing subscription and deploy three models on it:

Deployment Model
Small chat GPT-5-mini class or equivalent
Flagship chat GPT-5 class or equivalent
Embeddings text-embedding-3-small

Hand over, via a secure channel: the endpoint URL, an API key, and the API version. Confirm outbound HTTPS from lin001 to the endpoint is permitted.

Pay-as-you-go. No fine-tuning and no provisioned throughput — both bill a fixed hourly amount whether used or not, and neither is needed.

Cost

Consumption-based, billed on usage only. No licence, no commitment, no minimum term, cancellable at any time. Estimated on three model calls per question at published list rates:

Usage Questions / month Estimated
Occasional demos 500 ≈ US$6
Expected — build, testing and demos 3,000 ≈ US$35
Heavy daily use 10,000 ≈ US$120

One-off cost to index the document set: under US$1.

Requested: a US$50 per month budget, approximately US$250 for the demo period, with an Azure budget alert set at that figure.

Rates are published list prices and should be confirmed at approval. This is a demonstration figure; an operational plant deployment would be sized and costed separately.

What it is for

The assistant runs end to end today except for the two steps that need a model: classifying each question, and wording the answer. Without the account those two cannot be built, tested or reviewed, and the 67-question acceptance test cannot be run at all.

(As delivered: both steps now run. The acceptance test is runnable and has grown to 75 cases, but has not yet been run as a formal Phase 8 gate — that is a task inside this project, not a request of anybody.)

2. Three public DNS records, plus pinpoint records on the DC — DELIVERED

Closed 27 August 2026. All three A records resolve to 20.211.144.151, and the DC carries the pinpoint record ai.yokogawa.tech → 10.0.0.17. Nothing further is needed from Dan for this item. Two things are worth recording:

  • api.yokogawa.tech and cube.yokogawa.tech have no pinpoint record, so they do not resolve from inside the VNet at all. That would have broken the operator demo, because the browser called the API by that hostname. Rather than ask for a fourth record, Caddy now routes /ask under ai.yokogawa.tech to ai-api and the page is same-origin. No further DNS is needed for the demo. cube.yokogawa.tech is for engineers on the public side only; ai-api reaches Cube container-to-container and never by hostname.

  • auth.yokogawa.tech has no pinpoint record either, and that was the defect this item missed. Confirmed 28 August 2026: it does not resolve from inside the VNet. Every Authelia-gated service redirects there, so a LAN browser reached ai.yokogawa.tech, got a correct 302 to the portal, and then died on DNS — the name resolved, the service answered, and the operator still saw "this site can't be reached". It went unnoticed because the device agents write to Influx over the /api/v2/write MFA bypass and never touch the portal; no browser had ever hit Authelia from inside the VNet. This is no longer needed for the operator path — on 28 August the console was made unauthenticated from cicore1 only (README §6, BUILD-AI-CONTAINERS.md §14) — but any other gated service browsed from the LAN will hit exactly this wall, so it is worth asking Dan for regardless.

  • The names resolving is not the same as the services answering. The Caddyfile blocks and the Authelia rules for ai, api and cube were applied on the host the same day; all four AI hostnames now return 302 to the auth portal. What is still unproven is the part no check here can reach: an operator on cicore1 — since 28 August, with no sign-in at all — getting an answer end to end.

The original request follows, unchanged.

What is needed

Three A records under yokogawa.tech, each → 20.211.144.151, the same treatment lf.yokogawa.tech already has:

Name Points at For
ai.yokogawa.tech 20.211.144.151 The operator's screen
api.yokogawa.tech 20.211.144.151 The assistant behind it
cube.yokogawa.tech 20.211.144.151 The data translator

And — separately, on the domain controller — a pinpoint record for ai.yokogawa.tech → 10.0.0.17. Azure hairpin means LAN hosts cannot reach the VM's public IP from inside the VNet, so without this an operator sitting at cicore1 cannot resolve the assistant at all. influx.yokogawa.tech already has exactly this treatment.

What it is for

All three services are running right now and none of them can be reached by name. Today they are opened down an engineer's SSH tunnel, which is fine for development and useless for a demonstration. No control-room PC can open the assistant until these records exist.

Caddy already holds the site blocks, each with import authelia, so sign-in and TLS are handled the moment the names resolve; certificates are issued automatically on first request. Access is governed by the existing HTTPS_UserAccess group — no new AD group is needed for this item.

Why raise it now

This is the item most likely to be forgotten, because nothing fails until the day somebody tries. Every container is healthy, every check passes, and the gap only appears when a person outside this project opens a browser. It also depends on two different people — public DNS and the DC are not the same change.

3. A read-only login to the imh historian

What is needed

  1. The server. yau-sls-poc-imh:1433 is configured and waiting; the host is still being built.
  2. svc_agent_ro created with SELECT on the agreed tables only — no DDL, no write access, no xp_ procedures. Password over a secure channel.
  3. The database name, and the agreed table names and key columns.
  4. NSG rule: lin001 → imh on 1433 only.
  5. Timestamp semantics confirmed: UTC or local, and DST behaviour. This one is not a formality — see below.
  6. Permission to set an application name on the connection, so DBAs can see who is connecting.

What it is for

Every figure the assistant produces today is a stand-in. Cube — the data translator — is running and answering questions against generated tables (32 alarm activations, 72 pump-downs, about 685,000 analogue samples over seven days), and every answer built on one carries a warning label all the way to the operator's screen. The definitions Cube uses are the real ones and will not change when the historian arrives; only the source will.

The stand-in is now keyed the same way the historian is. It was rebuilt on 2026-08-31 against WRPS/05-scada/modbus — CI Server item names, the real historisation groups, the real sample rates and the real retention. Three defects that had been left open closed as a result, and the schema conversation below is correspondingly narrower than it was: the shape is now right, and what remains is names.

Why the schema conversation is still needed

  • What imh calls these tables and columns. One item-keyed history table is the right shape; fixture.item_history is our guess at its name. Everything else — alarms, pump-down operations — is derived from it, so this is the only naming question that actually blocks anything.
  • Whether imh exposes CI Server's ALARM_HISTORY group at all. It exists on the server and is empty: every WRPS item was imported with alarming off and limits at 0, which 05-scada/modbus/README.md records as engineering judgement nobody has made yet. Alarms are derived from the PLC alarm word instead, which needs no configuration that does not exist. If someone does configure item alarm limits, we would rather use them.
  • An engineer must confirm Cube's first real numbers by hand before anybody trusts one. The stand-in asserts its own counts at load and cross-checks them two ways, but that proves the pipeline, not the plant. This is a person's time, not just a login.

A separate request: extend the historian's retention

Every WRPS history group is LIFE_TIME "1 weeks". The assistant therefore cannot answer a question about anything older than seven days — not badly, but at all. "How did last month compare with this one", "when did we last spill", "how many trips this quarter" are all outside reach, and they are among the questions an operator is most likely to ask.

The system now reports this honestly: a window reaching past retention is answered as "the historian does not go back that far", never as "no records found", because those are different answers and only one is true. But honest is not the same as useful.

Asked for: raise LIFE_TIME on WRPS_ONE_SEC, WRPS_THIRTY_SEC and WRPS_EVENT to at least 90 days, or confirm that seven days is a deliberate constraint we should design around and stop asking. Storage is the trade: the 5-second group is five items, which is roughly 120,000 samples per item per week.

Also worth a decision while someone is in there: the repository's his_group.qli and the live server's export_his_group.qli disagree about sample rates — the file says 1 s and 60 s, the server runs 5 s and 30 s. The live server was taken as authoritative. The repository does not currently describe the running system, and one of the two should change.

What it unblocks

Phase 4 and the remainder of Phase 5.

Related, but not a request

Phase 9 — operator document management will need a second AD group, AI_DocPublishers, with direct membership (Authelia resolves direct membership only; a user nested inside a group is silently denied). That is deliberately held until Phase 8 passes and is not being asked for now — noted here only so it is not a surprise later.