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Author SHA1 Message Date
rock d21ee9630f 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.
2026-10-13 08:09:42 +08:00
rock e4caa7e841 fix(etcd): make the defrag CronJob runnable and 15-day
The committed CronJob could never run, for two independent reasons:
- quay.io/coreos/etcd ships no /bin/sh, so command: [/bin/sh, -c] died with
  exec: "/bin/sh": no such file or directory
- it existed only on branch fix/etcd-defrag-cron, while the ArgoCD application
  cluster-maintenance tracks main (targetRevision: main), so the cluster never
  had the CronJob or its Secret

This revision fixes both and records the 2026-10-07 incident:
- image bitnamilegacy/etcd:3.6.4 pinned by digest (ships bash and etcdctl 3.6.4,
  matching the 3.6.11 servers)
- 15-day cadence by UTC epoch-day modulo; */15 in day-of-month fires on the 1st,
  16th and 31st, which puts two runs one day apart
- compacts to the MINIMUM revision across members, so a lagging member is never
  compacted past its own revision (measured: talos-cp-2 froze ~1.2M entries
  behind the leader and needed a reboot to rejoin)
- skips defrag on a member whose applied index lags the leader by 100k+
- documents that compact must precede defrag: compaction had stalled while the
  NOSPACE alarm was up, so dbSizeInUse read 100% of the file and defrag alone
  would have reclaimed nothing
2026-10-07 17:11:35 +08:00
harness 1ce9f86635 feat(etcd): weekly defrag CronJob to stay under the etcd backend quota
etcd's 2 GiB quota was reached on 2026-10-07 (backend 2.1 GiB, ~73 days of
churn). etcd raised NOSPACE and refused all writes, so kubelets could not post
node status: three nodes went NotReady and the tunnel origin pods on them
disappeared. Recovery was compact + defrag + alarm disarm per member.

The apiserver compacts every 5m, but compaction never shrinks the backend file -
only a defrag returns space, and nothing scheduled it. This adds:

- CronJob etcd-defrag (kube-system, Sundays 03:00): compact to the current
  revision, defrag each member sequentially, disarm NOSPACE, print before/after.
- Secret etcd-defrag-creds (SOPS/ksops, k8s/argocd/secrets): etcd CA plus a
  CN=etcd-defrag client cert signed by the cluster's etcd CA (expires 2036-10).

Applied by the existing apps: cluster-maintenance (directory) and 00-secrets
(ksops generator).
2026-10-07 13:37:45 +08:00
5 changed files with 226 additions and 11 deletions
@@ -0,0 +1,27 @@
apiVersion: v1
kind: Secret
metadata:
name: etcd-defrag-creds
namespace: kube-system
labels:
app.kubernetes.io/name: etcd-defrag
type: Opaque
stringData:
ca.crt: ENC[AES256_GCM,data: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,iv:KnW9LYNzxZ6r3Q6LTeOrgSLLPgiJlibVp6YmTEKBkjE=,tag:KTL1nOWdNWDA4dLVaA4//g==,type:str]
client.crt: ENC[AES256_GCM,data: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,iv:l8BwxxEfHfYrm+mM5UE6Yj42DeeU9y23jjIE1KjIiME=,tag:HwRT6/myIsxc84BYDj3K6w==,type:str]
client.key: ENC[AES256_GCM,data:QD/Glf3lFslBEdEoJ3CNrYzlw2HLCvGSeVuJLtxnFne2aJOuw0sk/e0h/kSAxvG4dZ+LIWJLLbqTjKHOAhkvS/ZOA7GSea4ubNkvTkw8+JBRuYwb2D2iB8kZhlER/CpiGkYJukjkgGP1CzHdvBY1M88pW9w6rH74MD3jY47qExIaNduQj5vkUQZ8ajqkd79l0nk98ZTawfPG4AFcEtAIKAPIuubT2GZ3qqNLjOI7agbtRv8xI44hhb2wj5J9xdl1GrbOWwG5EOo+hLNrcAAOCcWBpNTUCKBy7mrk2ID8jX3HsFWN76DDlQzkhcphMhlM7g==,iv:49HGJAEgllEkB3YSiZLmbWs/vlbFbY52kiKesdGVC/Y=,tag:g8YZ9at3V2l6RFRfvO2lAQ==,type:str]
sops:
age:
- enc: |
-----BEGIN AGE ENCRYPTED FILE-----
YWdlLWVuY3J5cHRpb24ub3JnL3YxCi0+IFgyNTUxOSB4Z0h0R2dhbDdRcFJydE9o
R0hWeCtwVzluZWZlR0VtOXcxdW9FbklOQXlzCmo3eXNyNlFjejNETkJiVVRVWFhr
a2pORnhIQTI0UUk2N3dWMDZJcEhYU1UKLS0tIEduaHlmMHQza1A0TGVZb0JrbTYz
MWJwQjcrdkkzQXhOTmhycERsM0FtNVEKG+gBRcvUsyfRzuW999EQNzyDh2/5fY6p
8ab2xvTOJPiMUBTBuQZsA+iDImytUO/02ROQsbEZkALijp1nqrsV/g==
-----END AGE ENCRYPTED FILE-----
recipient: age1e5fq3hwxy78psus2nfvmtmua36g0u3suk78ephw6246l974d2utsvn0hla
encrypted_regex: ^(data|stringData)$
lastmodified: "2026-10-07T05:37:26Z"
mac: ENC[AES256_GCM,data:vu6ltV0jYQNGV4eqIcqAp9p2TJ8ULBX5JBELUgm/nA9GX+I6Pv3fyjpcHRSWY0HbLvCwgXd22CG4IYcj4HJFtQGZR7OcQA5WM5plZH3RCPdvPNix/798vkETfpJxorQjlHoq4nlr3dEmUCbzdtE07qV2W1M6GJr4C9xKvB947bQ=,iv:aA9mjZCFAoLEhGqkl6NfyBZ3x3vWGfLYYAEe8jXuA4U=,tag:Drdiji33ckDd8ildpvSEXw==,type:str]
version: 3.13.2
+1
View File
@@ -34,3 +34,4 @@ files:
- forgejo-smtp-secrets.enc.yaml
- paperless-ai-secrets.enc.yaml
- pi-sandbox-secrets.enc.yaml
- etcd-defrag-creds.enc.yaml
@@ -0,0 +1,177 @@
# etcd backend maintenance: compact, defrag, disarm NOSPACE.
#
# Why this exists
# ---------------
# etcd's backend file only grows. The apiserver compacts every 5m, but
# compaction marks superseded revisions free *inside* the file; only `defrag`
# returns that space to the filesystem. Nothing ran defrag, so the file grew
# until it crossed the 2 GiB quota:
#
# 2026-10-07 backend 2,148,843,520 B (2.1 GB) on talos-cp-1 and talos-cp-3
# -> etcd raised NOSPACE on those two members
# -> etcd rejected ALL writes cluster-wide
# -> kubelets could not post node status: 3 nodes NotReady
# -> apiserver writes returned 500, the tunnel API path 502
#
# The live data was tiny: 15,943 keys, 69 MB after compaction. The rest was
# dead pages. Recovery was `compact <current-revision>` then `defrag` per
# member then `alarm disarm`. Compaction had also stalled while the alarm was
# up, so `dbSizeInUse` read 100% of the file - defrag alone would NOT have
# worked. Order matters: compact first, then defrag.
#
# The earlier revision of this file never ran, for two independent reasons:
# 1. it existed only on branch fix/etcd-defrag-cron; the ArgoCD application
# `cluster-maintenance` tracks `main` (targetRevision: main), so the
# cluster never had the CronJob or the Secret.
# 2. the image was quay.io/coreos/etcd, which has NO /bin/sh (verified:
# `exec: "/bin/sh": no such file or directory`). Any container that runs
# a shell script needs an image that ships one.
# This revision fixes both: image bitnamilegacy/etcd (ships bash + etcdctl
# 3.6.4, matching the 3.6.11 servers) pinned by digest.
#
# Cadence: every 15 days. Measured growth is ~29 MB/day, so a 15-day cycle
# peaks near 500 MB - comfortably under the 2 GiB quota. The schedule is daily
# and the script exits unless the UTC epoch day is a multiple of 15. That gives
# an exact 15-day interval; `*/15` in the day-of-month field does not (it fires
# on the 1st, 16th and 31st, which puts two runs one day apart).
#
# Safety
# ------
# 1. Compaction uses the MINIMUM revision across members. Compacting to a
# revision a member has not reached wedges that member - measured on
# 2026-10-07, when talos-cp-2 froze ~1.2M entries behind the leader and
# needed a reboot to rejoin.
# 2. A member whose raft applied index lags the leader by more than 100000 is
# skipped and reported. Defragging a frozen member reclaims nothing.
# 3. Members are defragged one at a time. A defrag pauses the member's apply
# loop for the duration of the file copy.
#
# Credentials: Secret etcd-defrag-creds in kube-system, SOPS-managed in
# k8s/argocd/secrets/etcd-defrag-creds.enc.yaml (ksops generator 00-secrets).
# Its client certificate is signed by the cluster's etcd CA and expires
# 2036-10; rotate it before then by re-running the mint and re-encrypting.
#
# Companion alerts (monitoring): etcd_mvcc_db_total_size_in_bytes /
# etcd_server_quota_backend_bytes > 0.8, and an etcd NOSPACE alarm alert.
apiVersion: batch/v1
kind: CronJob
metadata:
name: etcd-defrag
namespace: kube-system
labels:
app.kubernetes.io/name: etcd-defrag
app.kubernetes.io/part-of: cluster-maintenance
spec:
schedule: "0 3 * * *" # daily; the script acts only every 15th day
concurrencyPolicy: Forbid
startingDeadlineSeconds: 600
successfulJobsHistoryLimit: 3
failedJobsHistoryLimit: 3
jobTemplate:
spec:
backoffLimit: 2
template:
spec:
restartPolicy: OnFailure
tolerations:
- key: node-role.kubernetes.io/control-plane
operator: Exists
effect: NoSchedule
containers:
- name: defrag
image: bitnamilegacy/etcd:3.6.4@sha256:c86c06f1ce6a08b6df21eb7a9655b1818778b64c85b5cbb8413ebf7534789730
env:
- name: ETCDCTL_API
value: "3"
- name: ETCDCTL_CACERT
value: /etc/etcd/ca.crt
- name: ETCDCTL_CERT
value: /etc/etcd/client.crt
- name: ETCDCTL_KEY
value: /etc/etcd/client.key
- name: EPS
value: "https://192.168.1.166:2379 https://192.168.1.214:2379 https://192.168.1.162:2379"
command: ["/bin/bash", "-c"]
args:
- |
set -u
DAY=$(( $(date -u +%s) / 86400 ))
if [ $(( DAY % 15 )) -ne 0 ]; then
echo "skip: UTC epoch day $DAY is not a 15-day boundary"
exit 0
fi
echo "== before =="
for ep in $EPS; do
etcdctl --endpoints="$ep" endpoint status -w table || true
done
MINREV=""
MAXAPPLIED=0
for ep in $EPS; do
json=$(etcdctl --endpoints="$ep" endpoint status -w json 2>/dev/null) || continue
rev=$(printf '%s' "$json" | sed -n 's/.*"revision":\([0-9]*\).*/\1/p' | head -1)
app=$(printf '%s' "$json" | sed -n 's/.*"raftAppliedIndex":\([0-9]*\).*/\1/p' | head -1)
echo "member $ep revision=${rev:-?} raftAppliedIndex=${app:-?}"
if [ -n "$rev" ] && { [ -z "$MINREV" ] || [ "$rev" -lt "$MINREV" ]; }; then
MINREV="$rev"
fi
if [ -n "$app" ] && [ "$app" -gt "$MAXAPPLIED" ]; then
MAXAPPLIED="$app"
fi
done
if [ -z "$MINREV" ]; then
echo "FATAL: no member returned a revision; nothing attempted"
exit 1
fi
echo "== compact to revision $MINREV =="
etcdctl --endpoints="$(echo "$EPS" | awk '{print $1}')" compact "$MINREV" || echo "COMPACT-FAILED (continuing: defrag still reclaims free pages)"
# Physical deletion of superseded keys runs in the background
# after the compaction commit; give it a moment to drain.
sleep 20
echo "== defrag each member (sequential, one at a time) =="
rc=0
for ep in $EPS; do
json=$(etcdctl --endpoints="$ep" endpoint status -w json 2>/dev/null) || { echo "SKIP $ep (unreachable)"; rc=1; continue; }
app=$(printf '%s' "$json" | sed -n 's/.*"raftAppliedIndex":\([0-9]*\).*/\1/p' | head -1)
if [ -n "$app" ] && [ "$app" -lt $(( MAXAPPLIED - 100000 )) ]; then
echo "SKIP $ep (applied index $app lags leader $MAXAPPLIED; defrag would reclaim nothing)"
rc=1
continue
fi
echo "-- $ep"
if ! etcdctl --endpoints="$ep" defrag; then
echo "DEFRAG-FAILED $ep"
rc=1
fi
done
echo "== disarm NOSPACE =="
for ep in $EPS; do
etcdctl --endpoints="$ep" alarm list 2>/dev/null || true
etcdctl --endpoints="$ep" alarm disarm 2>/dev/null || true
done
echo "== after =="
for ep in $EPS; do
etcdctl --endpoints="$ep" endpoint status -w table || true
done
etcdctl --endpoints="$(echo "$EPS" | awk '{print $1}')" alarm list || true
exit $rc
resources:
requests: { cpu: 10m, memory: 32Mi }
limits: { cpu: 200m, memory: 128Mi }
volumeMounts:
- name: creds
mountPath: /etc/etcd
readOnly: true
volumes:
- name: creds
secret:
secretName: etcd-defrag-creds
defaultMode: 0444
+13 -10
View File
@@ -41,13 +41,24 @@ spec:
# - /var/lib/longhorn-disk1 (sdb1, 600GB)
# - /var/lib/longhorn-disk2 (sdc1, 500GB)
# - /var/lib/longhorn-disk3 (sdd1, 160GB)
# - /var/lib/longhorn-disk4 (sde1, 2TB)
#
# /var/lib/longhorn-disk4 (sde1, the 2TB PERC virtual disk) was RETIRED
# on 2026-10-12 and must not be re-added. The device returned SCSI I/O
# errors at ~7,000/minute, the XFS filesystem on it hung, and every
# process that touched it blocked in unkillable D state. Those unkillable
# processes held Longhorn's per-node rebuild slots forever, so no new
# replica could start on talos-cp-2 and every new volume there failed to
# attach. It is removed from the Terraform disk list too, so a re-render
# does not put it back.
echo "Checking talos-cp-2..."
CURRENT_DISKS=$(kubectl -n longhorn-system get nodes.longhorn.io talos-cp-2 -o json | jq -r '.spec.disks | keys | length')
echo " Current disk count: $CURRENT_DISKS"
if [ "$CURRENT_DISKS" -lt 5 ]; then
# 4 = default-disk-080400000000 + disk1..disk3. It was 5 while disk4
# existed; leaving the old threshold would re-apply the patch on every
# run once disk4 is gone.
if [ "$CURRENT_DISKS" -lt 4 ]; then
echo " Adding extra disks to talos-cp-2..."
kubectl -n longhorn-system patch nodes.longhorn.io talos-cp-2 --type merge -p '{
"spec": {
@@ -75,14 +86,6 @@ spec:
"path": "/var/lib/longhorn-disk3",
"storageReserved": 5368709120,
"tags": []
},
"disk4": {
"allowScheduling": true,
"diskType": "filesystem",
"evictionRequested": false,
"path": "/var/lib/longhorn-disk4",
"storageReserved": 21474836480,
"tags": []
}
}
}
+8 -1
View File
@@ -20,6 +20,7 @@ controlplane_configs = {
"talos-cp-1" = {
hostname = "talos-cp-1"
lan_ip = "192.168.1.166"
public_ip = "https://k8s-api.riotpiao.com"
lan_subnet = "192.168.1.0/24"
lan_gateway = "192.168.1.254"
install_disk = "/dev/nvme0n1"
@@ -32,6 +33,7 @@ controlplane_configs = {
"talos-cp-2" = {
hostname = "talos-cp-2"
lan_ip = "192.168.1.214"
public_ip = "https://k8s-api.riotpiao.com"
lan_subnet = "192.168.1.0/24"
lan_gateway = "192.168.1.254"
install_disk = "/dev/disk/by-id/wwn-0x644a842029bd3f002720989b07d7143d"
@@ -39,7 +41,11 @@ controlplane_configs = {
{ device = "/dev/disk/by-id/wwn-0x644a842029bd3f0031b60f4375d97062", mountpoint = "/var/lib/longhorn-disk1" },
{ device = "/dev/disk/by-id/wwn-0x644a842029bd3f0031b5ffeb8bb8b47f", mountpoint = "/var/lib/longhorn-disk2" },
{ device = "/dev/disk/by-id/wwn-0x644a842029bd3f0031b6000c8dabb266", mountpoint = "/var/lib/longhorn-disk3" },
{ device = "/dev/disk/by-id/wwn-0x6b083fe0c5782700321370dc23fd765b", mountpoint = "/var/lib/longhorn-disk4" },
# /var/lib/longhorn-disk4 (wwn-0x6b083fe0c5782700321370dc23fd765b) was
# retired 2026-10-12: the 2TB PERC virtual disk failed with continuous
# SCSI I/O errors, hung its XFS filesystem, and wedged Longhorn replica
# rebuilds on talos-cp-2 with unkillable D-state processes. Do not
# re-add it.
]
zone = "az-b"
allow_scheduling = true
@@ -49,6 +55,7 @@ controlplane_configs = {
"talos-cp-3" = {
hostname = "talos-cp-3"
lan_ip = "192.168.1.162"
public_ip = "https://k8s-api.riotpiao.com"
lan_subnet = "192.168.1.0/24"
lan_gateway = "192.168.1.254"
install_disk = "/dev/nvme0n1"