Cases19 cases

2 to 6 of 19

1. IL-0098 After 2i2c moved from ingress-nginx to nginx-ingress, a hub's Ingress took priority over cert-manager's temporary Ingress for the same host, so new hubs could not get TLS certificates

   2i2c2026

   Symptoms

   An attempt to launch a new hub failed because its ingress could not obtain a new TLS certificate. The day before, the same engineer had recreated the support deployment on the 2i2c-aws-us cluster and seen its TLS certificate orders stuck pending.

   Misrouted requestsDeploys failing

   Trigger

   Creating new hub deployments that needed new TLS certificates on clusters recently migrated from ingress-nginx to nginx-ingress.

   Root cause

   Breaking change in an upgrade

   Component

   Ingress controllercert-manager

   Contributing factor

   Change with a delayed effect

   Detection

   An attempt to launch a new hub failed; the engineer had seen certificate orders stuck pending on another cluster the day before and declared an incident.

   Remediation

   • annotated the Ingress objects that need TLS so that cert-manager could edit them in place to complete the ACME challenge

   Action items

   • Follow-up tracked in https://github.com/2i2c-org/infrastructure/issues/8016
   • Follow-up tracked in https://github.com/2i2c-org/infrastructure/issues/3278

   Lessons

   Swapping one ingress controller for another can change how Ingress objects that share a host are combined. cert-manager's temporary challenge Ingress depends on that behaviour, so the breakage shows up when a deployment needs a new certificate. 2i2c notes that it got lucky: it had already learned of this possible cause while testing on an internal cluster, and changing the cert-manager configuration was quick.

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2. IL-0092 Upgrading ingress-nginx from 1.12.0 to 1.14.3 brought a newer ModSecurity and OWASP Core Rule Set whose false positives blocked HMPPS Auth, so users could not sign in to their applications

   UK Ministry of Justice2026

   Symptoms

   At 08:56 on 30 March 2026, about an hour and three quarters after the rollout of a new ingress-nginx to production began, the MoJ Cloud Platform team noticed messages in the #hmpps-auth-audit-registers Slack channel about ModSecurity unexpectedly blocking requests. Users in HMPPS also raised incidents with the MoJ service desk.

   High error rateService outage

   Trigger

   The Cloud Platform team began deploying ingress-nginx 1.14.3, on images maintained by Chainguard, to the three production ingresses at 07:11 on 30 March 2026.

   Root cause

   Breaking change in an upgrade

   Component

   Ingress controllerWeb application firewall rules

   Contributing factor

   Unrepresentative staging

   Detection

   At 08:56 the Cloud Platform team saw messages in the #hmpps-auth-audit-registers Slack channel showing ModSecurity blocking requests unexpectedly; HMPPS users also raised incidents with the MoJ service desk.

   Remediation

   • rolled the ingress-nginx deployment back to the previous version, from 09:14 to 09:43
   • HMPPS applied ModSecurity rule exclusions for the rules blocking traffic to HMPPS Auth
   • added a temporary global exclusion for the CRS rule triggered by the PostHog cookie
   • redeployed ingress-nginx 1.14.3 with both exclusions in place, completed at 14:00

   Action items

   • Rescope the PostHog cookie so it is no longer sent with requests to all *.justice.gov.uk services
   • Remove the temporary global exclusion once the PostHog cookie has expired from enough users' browsers
   • Remind service teams to run dev and test workloads through the non-production ingress controllers so future ModSecurity and CRS updates are tested
   • Run production and non-production workloads in separate clusters in Cloud Platform 3.0, so non-production workloads must use the non-production ingress

   Lessons

   An ingress controller upgrade that bundles a web application firewall also changes which requests are allowed, not only how they are routed. A beta or non-production ingress only catches false positives for traffic that actually passes through it, and teams that keep their test workloads on the production ingress miss them. A fix on the client side, such as rescoping a cookie, takes effect only when old cookies have expired in users' browsers, so the rule change has to wait for it or ship with an exclusion.

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3. IL-0236 After an Istio 1.15 to 1.24 upgrade, half of Wikimedia's ML model servers returned 5XX for about a day

   Wikimedia Foundation2026

   Symptoms

   From 17:30 UTC on 23 February 2026, right after the ml-serve-codfw Kubernetes cluster was upgraded, 5XX responses appeared in the metrics of a subset of Wikimedia's machine learning model servers and alerts started to fire. About half of the running model servers were affected and stayed unreachable for roughly 24 hours.

   High error rate

   Trigger

   The two production Machine Learning Kubernetes clusters were upgraded to version 1.31, which included upgrading Istio from 1.15 to 1.24; ml-serve-codfw was done at 17:21 UTC on 23 February and ml-serve-eqiad between 08:00 and 11:00 UTC on 24 February.

   Root cause

   Breaking change in an upgrade

   Component

   IstioModel inference server

   Contributing factor

   Ignored early signal

   Detection

   Users of the affected model servers first reported the issue in the talk-to-machine-learning Slack channel. Alerts for HTTP 5XX had fired in the Machine Learning IRC channel right after the codfw upgrade, but nobody on the team noticed them.

   Remediation

   • Deployed an Istio hot patch that restored the broken functionality and fixed most of the HTTP 500 errors
   • Deployed the permanent fix to all affected clusters after verifying it on ml-staging-codfw

   Action items

   • Deliver alerts to the relevant Slack channels and watch IRC or alerts.wikimedia.org
   • Add more SLOs and fix the existing ones, whose Istio metrics changed

   Lessons

   The problem could have been caught on the staging cluster first, or by ad-hoc testing within the team after each cluster upgrade, which had been requested when the upgrades were announced. Not everyone involved knew that httpbb tests existed, and nobody on the Machine Learning team saw the alerts that fired right after the codfw upgrade. Recovery was fairly quick once users reported the problem, helped by having the right person online to find the Istio hot patch.

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4. IL-0405 An expired AWS Load Balancer Controller webhook certificate left no healthy targets and took BSEE SaaS down

   PortSwigger2026

   Symptoms

   From 10:00 UTC on 11 January 2026 every BSEE SaaS instance in PortSwigger's US and Canada regions was unavailable: customers could not open the Web UI or start scans. The platform team learned of it only when customers reported it through support at 09:52 UTC the next day.

   Service outageTLS certificate errors

   Trigger

   The upgrade of the AWS Load Balancer Controller from v1.14.1 to v1.16.0 on 28 November 2025 left an orphaned webhook TLS secret that cert-manager could not renew, and the certificate in it expired on 8 January 2026.

   Root cause

   Breaking change in an upgrade

   Component

   Ingress controllerAdmission webhookcert-managerHelmConfigMaps and SecretsCloud load balancer

   Contributing factor

   Change with a delayed effectMonitoring blind spot

   Detection

   Customers reported the outage through support at 09:52 UTC on 12 January 2026, almost 24 hours after impact began, and the platform team began investigating at 10:00 UTC.

   Remediation

   • Deleted the orphaned aws-load-balancer-tls secrets in the US and Canada clusters
   • Redeployed the AWS Load Balancer Controller configuration with Helm
   • Verified that new certificates were generated and the webhooks worked again

   Action items

   • Audit all clusters for orphaned secrets that have no owning Certificate resource and resolve them
   • Add high-level application access alerting for each SaaS cluster from an external probe

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5. IL-0101 After Google forced a GKE control plane upgrade to 1.33.2 at a deprecation deadline, no new node could initialise, so autoscaling and spot node replacement stopped for 15 hours

   Wealthy2025sev1

   Symptoms

   Nodes that already existed kept running, but every new node, spot or standard, on either v1.32 or v1.33, failed to initialise and could not join the cluster. Spot nodes that were preempted and recreated never came back, so services degraded progressively: background workers on spot instances, reporting services and order allocation stopped completely, and the APIs on existing nodes kept answering but could not scale for load spikes.

   Scale-up failureContainer crash loopService outageDNS resolution failures

   Trigger

   Google upgraded the GKE control plane from v1.32.x to v1.33.2 at the version deprecation deadline, although auto-upgrade was disabled on the node pools.

   Root cause

   Breaking change in an upgrade

   Component

   GKE control planeNode poolClient-side DNS resolver and cachePersistent volumes and stateful setsConfigMaps and Secrets

   Contributing factor

   Deferred upgradesSingle point of failureIneffective rollbackNo headroom

   Remediation

   • Created a new GKE cluster at v1.33, the version of the forced upgrade
   • Upgraded Istio to 1.27.1 for Kubernetes 1.33 compatibility
   • Updated the cert-manager configuration for Kubernetes 1.33
   • Migrated all production workloads to the new cluster and verified pod scheduling, DNS resolution, PVC mounting and external integrations
   • Decommissioned the broken cluster

   Action items

   • Configure all clusters to use the GKE stable release channel
   • Implement a separate management cluster for Argo CD, monitoring and other control components (Q4 2025)
   • Review spot instance usage for critical workloads and add on-demand fallback pools
   • Document the SRE upgrade procedure: management cluster first, production after a monitoring period of several days
   • Document a Kubernetes, Istio and cert-manager compatibility matrix
   • Create an automated upgrade testing pipeline
   • Reserve static IPs for quick migrations
   • Pin versions of Istio, cert-manager, CSI and DNS addons
   • Stay current with stable releases and regularly check GKE alerts and announcements to avoid deprecation deadlines

   Lessons

   GKE upgrades the control plane at a version's deprecation deadline even when auto-upgrade is disabled, so staying inside the supported version window is how to avoid a forced upgrade. A control plane upgrade can leave existing nodes healthy while every new node fails, and spot nodes that cannot rejoin after preemption turn this into cascading failures. Relying heavily on spot instances for critical workers turned a node join failure into a progressive outage. Kubernetes upgrades have to be planned together with dependent components such as Istio and cert-manager, and without a standby cluster on the same provider there was no immediate failover; the only recovery left was building a new cluster.

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