Incident Library
  • Root cause
  • Component
  • Symptom
  • Contributing factor
  • Case

Cases11 cases

9 to 11 of 11

  1. Symptoms

    Between 5:42 AM and 7:16 AM PT on 8 November 2023 a large share of requests to OpenAI failed with 502 or 503 errors. Every model and API endpoint saw significant failures.

    Trigger

    A morning with dramatically more completions than any previous day pushed the routing layer nodes, which already had a chronic memory problem, past their memory limits.

    Root cause
    Component
    Contributing factor
    Remediation
    • limited incoming traffic
    • redeployed the routing service en masse
    • ramped traffic back up slowly
    Action items
    • Pre-allocate the responseBuffer and reuse it instead of allocating a new one in a loop (3X improvement in memory and CPU usage)
    • Adjust the configured memory limits to an appropriate level so the service has significant headroom
    • Add rate limit controls to shed traffic more gracefully
    • Increase the service's capacity
    • Change alerting to catch the underlying memory behaviour before it escalates into service issues
    • Configure autoscaling for the service, which was not possible before because added capacity could hurt an upstream service
  2. Symptoms

    At 4:53 pm Pacific on 25 January 2023 one of OpenAI's GPU clusters had a major outage, and the text-davinci-003 model went fully down.

    Trigger

    A configuration change to the CNI (Container Network Interface) plugins, which provide network connectivity to containers, was deployed to a GPU cluster that contained a hardware variant the staging environment did not have.

    Root cause
    Component
    Contributing factor
    Detection

    Engineers immediately identified the problem as network connectivity, but it took nearly an hour to identify CNI as the cause.

    Remediation
    • put a fix for the CNI configuration change in place, which restored 80% of traffic immediately
    • deployed models back onto GPUs over about three more hours until capacity was fully stable
    Action items
    • Make staging environments contain every type of hardware configuration so they better represent production
    • Monitor and alert on the health of the CNI system directly
    • Fix the network and storage bottlenecks that limit how quickly many replicas of a model can be deployed
    Lessons

    A change that had been deployed to other clusters over 24 hours and deemed safe still broke a cluster with different hardware, so staging needs every hardware configuration that production has.

  3. Symptoms

    At 18:56 PDT on 23 June 2022 (01:56 UTC on 24 June) several models went offline at once: some fine-tuned curie and davinci models, the Codex beta models code-davinci-001 and code-cushman-001, the legacy GPT models curie, babbage and ada, and all Embeddings models.

    Trigger

    A destructive operation on one of the three production clusters, caused by human error that the existing safeguards did not catch, took the whole cluster offline.

    Root cause
    Component
    Contributing factor
    Remediation
    • re-allocated the models from the lost cluster to the remaining two clusters
    • rebuilt the VPN link with Azure support after losing the connection to AKS during cluster setup
    • built workarounds with Azure support after losing the connection to Azure Private Link
    • tore down the cluster and rebuilt it from scratch after the upgraded Kubernetes version broke the ingress
    • moved traffic back into the rebuilt cluster between 05:30 and 06:30 PDT
    Action items
    • Add checks and locks so that this and similar production-critical infrastructure cannot be modified by accident
    • Add better visibility into the operations being performed and make parts of the system more lexicographically distinct
    • Keep working with Azure on the AKS network connectivity issues so they do not disrupt new cluster operations
    • Update playbooks with the new cluster failure modes and change the setup steps for new clusters and infrastructure
    • Upgrade Kubernetes systematically and set aside time so the clusters do not fall behind again
    • Shard fine-tuned models across multiple clusters and work towards more automatic cross-cluster replication
    • Distribute and replicate Azure Blob Storage so fine-tuned models load faster and more reliably
    • Finish rolling out node-to-node caching to relieve Azure Blob Storage bottlenecks
    • Change how model weights are stored so they are more efficient and faster to load
    Lessons

    Losing one of three clusters exhausted the GPU headroom, and GPUs could not be added on short notice, so full recovery depended on bringing the same cluster back. Rebuilding it exposed a deferred Kubernetes upgrade: the newer version broke the ingress, and because AKS cannot downgrade there was no way back except a full rebuild. Recovering many large models at once is limited by the bandwidth of the storage they load from, and the caches that normally hide this do not help when everything moves to a different cluster.

Check your cluster for this

These 11 cases involve Application database and Ingress controller. kubegap audits a Kubernetes cluster for gaps like these, read-only, from Claude Code or Codex; its checks cite public reports like the ones in this library.

By root cause6

Software defect2 cases

Organisation
  1. IL-0124 Capacity changes queued while a circuit breaker was engaged ran all at once when it was released, taking multiple OpenAI inference engines out of service and raising API error rates
    OpenAI2026
  2. IL-0123 A response buffer allocated anew in a loop made OpenAI's routing layer nodes hit their memory limits and fail readiness checks on a morning with more completions than any day before, causing 502 and 503 errors across all models
    OpenAI2023

Configuration change4 cases

Organisation
  1. IL-0122 An invalid value in a configuration shared by several ChatGPT services put pods into crash loops and raised error rates
    OpenAI2025
  2. IL-0005 A new telemetry service overloaded the Kubernetes API servers of large clusters and broke DNS-based service discovery for all OpenAI services
    OpenAI2024
  3. IL-0118 A global change to Kubernetes namespace labels made the networking layer recompute metadata and overwhelmed the control planes of three of OpenAI's largest GPU clusters
    OpenAI2024
  4. IL-0116 A CNI configuration change incompatible with a hardware variant that exists only in production cut network connectivity in an OpenAI GPU cluster and took text-davinci-003 fully down
    OpenAI2023

Faulty deployment1 case

Component
–
Organisation
  1. IL-0121 A faulty code change to a control plane cluster meant for low-priority workloads degraded the production inference workloads it also managed
    OpenAI2025

Breaking change in an upgrade2 cases

Organisation
  1. IL-0120 A daily scheduled OS update restarted systemd-networkd on cloud-hosted GPU nodes, which conflicted with OpenAI's networking agent and removed all routes, cutting capacity for ChatGPT and the API
    OpenAI2025
  2. IL-0117 A scheduled maintenance and an ingress upgrade on OpenAI's user-facing clusters caused a networking control plane regression that briefly broke the data plane, and the services that restarted then overwhelmed a backend persistence store with a heavy first-start query
    OpenAI2024

Cloud provider outage1 case

Organisation
  1. IL-0119 ChatGPT web service pods crash-looped on failing health checks after a Cosmos DB failure, leaving too few healthy pods to serve the web layer
    OpenAI2025

Operator error1 case

Organisation
  1. IL-0115 One of OpenAI's three production AKS clusters went offline through a human error, and rebuilding it took 10½ hours because an AKS Kubernetes upgrade broke the ingress and AKS cannot be downgraded
    OpenAI2022