Cases8 cases

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1. IL-0112 The daily node rollover put DFDS's EKS nodes on an AMI later recalled for a kernel issue, causing "PLEG is not healthy" NodeNotReady flaps and pod network timeouts

   DFDS2022

   Symptoms

   On 2022-10-31 a planned upgrade of the vpc-cni EKS add-on, started from the deployment pipeline at 13:45 UTC, timed out at 14:10. Only about 10 of the 45 aws-node pods had upgraded, 5 were stuck in Terminating and the other 30 had not been attempted.

   Node NotReadyUpgrade stallIntermittent timeoutsIntermittent connection failures

   Trigger

   At 07:30 UTC on 2022-10-31 the daily node rollover replaced the existing nodes with nodes built from AMI v20221027, the latest AWS EKS node AMI, released on 2022-10-29 and later recalled because of a kernel issue.

   Root cause

   Software defect

   Component

   Node operating system imageLinux kernelkubeletAWS VPC CNINode launch templateTerraform

   Contributing factor

   No staged rolloutAutomation amplificationOverlapping failuresMonitoring blind spotNo health probes

   Detection

   The team noticed nodes flapping between NodeNotReady and NodeReady ("KubeletNotReady PLEG is not healthy") at 14:30 UTC while watching the stalled vpc-cni upgrade, about seven hours after the rollover. Time to detection was 7 hours. Alerting did not catch the NodeNotReady events or the socket growth.

   Remediation

   • cordoned, drained and deleted 15 stuck nodes one at a time to complete the vpc-cni upgrade
   • changed the Terraform infrastructure-modules so a specific AMI could be set
   • rolled the EC2 Auto Scaling group launch configuration back to the previous known good AMI through the pipeline

   Action items

   • Reach out to teams with suggestions about readiness and liveness probes
   • Create a dashboard for readiness and liveness probe coverage
   • Write a wiki article on readiness and liveness probes and their usefulness
   • Modify infrastructure-modules to allow specifying a particular AMI
   • Schedule a discussion on whether to take the latest AMI immediately and how to test new AMIs before they are deployed
   • Implement alerting on abnormal NodeNotReady events and on increased socket use
   • Create a learning path for Kubernetes within the team
   • Collect logs from nodes centrally
   • Create a Prometheus exporter that retrieves the latest available AMI, with a dashboard and alerts

   Lessons

   When a new node AMI has just been rolled out, upgrading other cluster components on the same day makes it hard to tell which change is causing trouble; here the vpc-cni upgrade on the same day confused matters. Taking the latest AMI automatically with no way to pin one meant a rollback first needed a Terraform change. The team also concluded that it needs better communication paths with application teams during incidents.

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2. IL-0107 Kyverno stuck in a crash loop behind a webhook with failurePolicy fail blocked every change to Kubernetes Service objects for 88 minutes

   DFDS2022

   Symptoms

   At 11:38 UTC on 3 August 2022 an end-user team told the platform team that applying a Service resource to one of the Kubernetes clusters failed.

   Deploys failingContainer crash loop

   Trigger

   A certificate chain in a third-party application expired, through no action of DFDS, and the outdated Kyverno installation got stuck in a crash loop.

   Root cause

   Certificate or credential expiry

   Component

   Policy engineAdmission webhook

   Contributing factor

   Deferred upgradesUnreviewed defaultsMonitoring blind spotIgnored early signal

   Detection

   An end-user team alerted the platform team at 11:38 UTC that applying a Service resource failed; the platform team started looking into it at 11:50 UTC.

   Remediation

   • reproduced the issue in a sandbox cluster and deployed the fix there first
   • updated Kyverno to a newer Helm chart version in the affected production cluster

   Action items

   • Implement monitoring on Kyverno
   • Create internal documentation on the Kyverno setup
   • Investigate the exact certificate issue in the third-party application
   • Consider changing the failurePolicy on ClusterPolicy resources going forward

   Lessons

   Operational issues should be added to the 'Ops Day to Day' board from the start.

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3. IL-0106 A malformed Traefik IngressRoute triggered a Traefik v2 bug once a node rollover restarted every Traefik pod, and all Kubernetes services returned 404

   DFDS2021

   Symptoms

   At 08:00 UTC on 2021-09-06 every service in DFDS's Kubernetes cluster answered with 404. Investigation started five minutes later.

   Service outageHigh error rateProbe failures

   Trigger

   The automated Kubernetes node rollover on 2021-09-06 restarted all the Traefik v2 pods, five days after a malformed IngressRoute manifest had been applied.

   Root cause

   Software defect

   Component

   Ingress controllerCloud load balancer

   Contributing factor

   Change with a delayed effectNo configuration testsExcessive blast radius

   Detection

   All services returned 404 from 08:00 UTC and root cause investigation started at 08:05. Time to detection was 5 minutes.

   Remediation

   • changed the ALB health check path, which made the targets healthy but did not stop the 404s
   • rolled back by hand to Traefik v1 as the main ingress controller
   • deleted the malformed IngressRoute by hand and confirmed the Traefik v2 bug
   • applied the changes upstream

   Action items

   • Upgrade Traefik to v2.5, where the bug is fixed, and verify that it removes the bug
   • Change the Traefik v2 health check path to something more robust
   • Set up an external liveness probe on the ingress controller
   • Consider workload segmentation to limit the blast zone
   • Look into monitoring the Traefik v2 API for rapid changes
   • Look into smoke testing during and after node rollover

   Lessons

   A malformed IngressRoute did nothing visible for five days and then took down all ingress when every Traefik v2 pod had restarted during a node rollover. Because Traefik v2 failed gracefully, the first signals pointed at the ALB health checks instead of at Traefik. On incident handling, the team concluded that appointing an incident manager could have helped, that the war room meeting should be recorded and a log book kept, that people not involved should only make suggestions in writing, and that a short first round of sharing thoughts and gut feelings is useful.

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4. IL-0111 Switching the main Kubernetes ingress controller from Traefik v1 to v2 stopped X-Forwarded headers being passed, which broke the Okta login flow for every service using Okta and stopped DFDS online bookings for over an hour

   DFDS2021

   Symptoms

   After the switch to Traefik v2, functional tests indicated that everything was fine, and this was reported on Slack at 08:44 UTC. The first sign of trouble came at 09:26 UTC, when a developer reported a high count of HTTP 307 redirects, especially on the Okta service. At 09:32 UTC the team learned that the online booking system was down.

   Service outage

   Trigger

   At 08:22 UTC the AWS load balancers were updated to send requests to the new Traefik v2 reverse proxy as part of the migration away from Traefik v1.

   Root cause

   Configuration change

   Component

   Ingress controllerCloud load balancer

   Contributing factor

   Missed in reviewMonitoring blind spot

   Detection

   A developer reported a high count of HTTP 307 redirects, in particular on the Okta service, at 09:26 UTC, 64 minutes after the change; six minutes later the team was told the online booking system was down. The functional tests run after the switch had not caught it.

   Remediation

   • Rolled back the switch to Traefik v2, putting rollback ahead of investigation because of how critical the booking system is

   Action items

   • Consider how critical announcements can be made more visible
   • Consider whether the ALBs used for testing should have been shared with the teams so they could test their own scenarios

   Lessons

   Cloud Engineering cannot test every application scenario on its own, even after testing its own applications for weeks. A header that changes value behind a new ingress controller, here x-forwarded-proto going from https to http, can break an authentication flow while basic functional tests still pass. DFDS asks whether diffing request headers before and after the migration would have shown the problem in advance.

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5. IL-0105 Replacing the AWS VPC CNI during a Terraform refactoring detached the ALB target groups, and every service in the Kubernetes cluster returned 503

   DFDS2021

   Symptoms

   At 08:29 UTC on 22 June 2021 alerts fired because all services in the Kubernetes cluster were returning 503. No inbound traffic was reaching the cluster. A customer reported the problem at 08:32.

   Service outageHigh error rate

   Trigger

   The pipeline replaced the AWS VPC CNI as part of a refactoring that moved EKS add-ons from kubectl to native Terraform management.

   Root cause

   Configuration change

   Component

   AWS VPC CNICloud load balancerTerraform

   Contributing factor

   Unverified assumptionNo configuration tests

   Detection

   Alerts fired at 08:29 UTC, eight minutes after the VPC CNI was replaced; a customer reported the issue at 08:32.

   Remediation

   • committed a fix that reverted the infrastructure-modules reference
   • re-triggered the pipeline after it failed on an AWS API timeout
   • let the pipeline reattach the target groups to the ALB

   Action items

   • Revert the ALB de-registration delay to the default of 300 seconds
   • Update the roll-over script to set the ALB de-registration delay to zero temporarily before a roll-over
   • Create an ingress test suite

   Lessons

   The change to the de-registration delay had been weighed mainly for performance. Critical pipeline runs should be watched while they run. Everyone should receive the alerts and react to them, and alert messages that were unclear should be reworded.

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