fix(longhorn): retire the failed 2TB PERC disk on talos-cp-2
The disk behind /var/lib/longhorn-disk4 (sde1, 2TB PERC H710P virtual disk) failed: 54 million SCSI I/O errors and climbing at ~7,000/minute, against 3 on every other device on the node. Its XFS filesystem hung, so five Longhorn replica processes and the longhorn-manager blocked in uninterruptible D state in openat and unlinkat. D-state processes cannot be killed, so they held the node's three replica rebuild slots permanently: no new replica could start on talos-cp-2 and every new volume there failed to attach with DeadlineExceeded. That is what stopped the azhi database from coming up. Removed from all three declarations so it cannot come back: - terraform.tfvars.local.bak, longhorn_disks for talos-cp-2 - the Longhorn add-disks Job, which would otherwise re-register it - the Job's disk-count guard, 5 -> 4, or it would fire on every run once the disk is gone The running cluster already has the disk fenced (allowScheduling=false, evictionRequested=true); the replicas are evicted and the device retired at the controller after that.
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@@ -41,13 +41,24 @@ spec:
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# - /var/lib/longhorn-disk1 (sdb1, 600GB)
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# - /var/lib/longhorn-disk2 (sdc1, 500GB)
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# - /var/lib/longhorn-disk3 (sdd1, 160GB)
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# - /var/lib/longhorn-disk4 (sde1, 2TB)
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#
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# /var/lib/longhorn-disk4 (sde1, the 2TB PERC virtual disk) was RETIRED
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# on 2026-10-12 and must not be re-added. The device returned SCSI I/O
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# errors at ~7,000/minute, the XFS filesystem on it hung, and every
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# process that touched it blocked in unkillable D state. Those unkillable
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# processes held Longhorn's per-node rebuild slots forever, so no new
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# replica could start on talos-cp-2 and every new volume there failed to
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# attach. It is removed from the Terraform disk list too, so a re-render
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# does not put it back.
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echo "Checking talos-cp-2..."
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CURRENT_DISKS=$(kubectl -n longhorn-system get nodes.longhorn.io talos-cp-2 -o json | jq -r '.spec.disks | keys | length')
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echo " Current disk count: $CURRENT_DISKS"
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if [ "$CURRENT_DISKS" -lt 5 ]; then
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# 4 = default-disk-080400000000 + disk1..disk3. It was 5 while disk4
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# existed; leaving the old threshold would re-apply the patch on every
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# run once disk4 is gone.
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if [ "$CURRENT_DISKS" -lt 4 ]; then
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echo " Adding extra disks to talos-cp-2..."
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kubectl -n longhorn-system patch nodes.longhorn.io talos-cp-2 --type merge -p '{
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"spec": {
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@@ -75,14 +86,6 @@ spec:
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"path": "/var/lib/longhorn-disk3",
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"storageReserved": 5368709120,
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"tags": []
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},
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"disk4": {
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"allowScheduling": true,
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"diskType": "filesystem",
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"evictionRequested": false,
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"path": "/var/lib/longhorn-disk4",
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"storageReserved": 21474836480,
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"tags": []
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}
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}
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}
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