Cases18 cases

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1. IL-0183 kubeadm's one-year leaf certificates expired, so kube-apiserver could not reach etcd, restarted in a loop and left the cluster unreachable

   ckck8032026

   Symptoms

   The cluster could not be reached from outside. On the control plane node, sudo systemctl status kubelet showed TLS handshake errors such as "http: TLS handshake error from 101.198.0.183:19517: tls: client requested unsupported application protocols" and "http: TLS handshake error from 101.198.0.172:36328: tls: client offered only unsupported versions: [302 301]".

   Control plane unresponsiveContainer crash loop

   Trigger

   The leaf certificates that kubeadm had generated for the cluster, valid for one year by default, expired at 2026-02-20 16:16 UTC.

   Root cause

   Certificate or credential expiry

   Component

   Kubernetes API serveretcdkubeletCalico

   Contributing factor

   Unreviewed defaults

   Detection

   The author could not connect to the cluster from outside and went to the control plane node to read the kubelet logs.

   Remediation

   • renewed all expired certificates with sudo kubeadm certs renew all
   • restarted containerd and the kubelet so the static control plane pods restarted with the new certificates
   • copied the renewed /etc/kubernetes/admin.conf to $HOME/.kube/config

   Lessons

   A kubeadm cluster stops working one year after its leaf certificates were issued unless they are renewed. The first errors seen may be TLS handshake failures or a flag error that does not mention certificates; the decisive message is the x509 expiry in the kube-apiserver log for its connection to etcd. The author recommends checking expiry with kubeadm certs check-expiration and renewing from 30 days before. kubeadm upgrade apply renews the certificates too, so a cluster upgraded at least once a year avoids the problem; a cluster run for a long time without upgrades can renew from cron, for example with 0 3 1 1 * root kubeadm certs renew all && systemctl restart kubelet in /etc/cron.d/kubeadm-cert-renew.

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2. IL-0138 A failed Nvidia driver build left broken kernel packages on the only Kubernetes master node, which hit a kernel panic on reboot after a power outage and took the homelab cluster down for six days

   Barush Mendez2025

   Symptoms

   Every service in the homelab Kubernetes cluster stopped answering: the V-Rising server, Grafana, Jellyfin and Linkding were all unreachable, and the Kubernetes API was down, so the cluster could not be managed at all. The outage was found by hand, about 3 hours after it began, when someone tried to use the services.

   Control plane unresponsiveService outageMonitoring outage

   Trigger

   A power outage forced the Kubernetes master node to reboot.

   Root cause

   Software defect

   Component

   GPU driverLinux kernelKubernetes API server

   Contributing factor

   Ignored early signalChange with a delayed effectSingle point of failureMonitoring blind spot

   Detection

   Manually, when someone tried to access the services; there were no automated alerts.

   Remediation

   • Connected a monitor to the master node and read the boot logs, which showed the kernel panic
   • Booted the previous kernel version, which brought the system back
   • Removed the broken Nvidia packages with sudo apt-get remove --purge '^nvidia-.*' and ran sudo dpkg --configure -a
   • Found remaining broken packages with dpkg -l | grep -v ^ii and removed them by hand
   • Ran sudo apt-get install -f and reinstalled linux-headers-$(uname -r)
   • Rebooted and confirmed the kernel panic was gone

   Action items

   • Make sure GPU driver installations fully succeed, or revert immediately when they fail
   • Move the cluster to a high-availability control plane
   • Expose the Kubernetes API through a load balancer in the HA setup
   • Set up a ticketing system to record incidents and their resolution
   • Write predefined troubleshooting workflows to shorten response time
   • Add infrastructure monitoring such as Prometheus and Grafana
   • Add blackbox HTTP and TCP checks from outside the cluster for critical services

   Lessons

   A driver installation that fails half-way can leave kernel packages broken without any visible effect until the next reboot, which may come weeks later and at the worst time. A failed DKMS build should be fixed or reverted at once. With a single master node and no monitoring from outside the cluster, one unbootable machine meant a total outage that nobody was told about; the fix itself was simple once the boot logs were seen.

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3. IL-0204 An etcd memory spike overloaded the control plane of a Render Frankfurt cluster, and DNS then failed because CoreDNS ran on the rebooted control plane nodes and could not start without the API server

   Render2024

   Symptoms

   In January 2022 an etcd memory spike overloaded the Kubernetes control plane of one of Render's clusters in Frankfurt. At first only operations that need the control plane failed: new deploys and cron job runs.

   Control plane unresponsiveDeploys failingDNS resolution failuresHigh error rate

   Trigger

   A memory spike in etcd overloaded the cluster's control plane.

   Root cause

   Capacity exhaustion

   Component

   etcdCoreDNSKubernetes API server

   Contributing factor

   Unreviewed defaultsHarmful manual action

   Action items

   • Run CoreDNS on data plane nodes instead of control plane nodes
   • Run etcd on dedicated nodes

   Lessons

   CoreDNS can keep answering from its in-memory cache while the API server is down, but it cannot initialise without it. With CoreDNS on the control plane nodes, a reboot or restart during a control plane outage turned a failure of deploys and cron jobs into a failure of requests to services that were already running. The core problem was that the data plane was not isolated enough from the control plane: even without the reboot, the etcd memory spike alone could have forced CoreDNS to restart.

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4. 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

   Symptoms

   Alerts fired at 3:13 PM PST on 11 December 2024, and from 3:16 PM every OpenAI service was significantly degraded or completely unavailable, including ChatGPT, the API and Sora. The status page reported API calls returning errors and difficulties logging in to platform.openai.com and ChatGPT. Customer impact peaked at 3:40 PM.

   Service outageHigh error rateControl plane unresponsiveDNS resolution failures

   Trigger

   At 2:23 PM PST a change introducing a new telemetry service, which collects detailed Kubernetes control plane metrics, was merged and the deployment pipeline started. Between 2:51 PM and 3:20 PM the change was applied to all clusters.

   Root cause

   Configuration change

   Component

   Kubernetes API serverClient-side DNS resolver and cacheTelemetry agent

   Contributing factor

   Unrepresentative stagingNo staged rolloutCache-masked failureMonitoring blind spotLimited debug access

   Detection

   OpenAI's detection tools worked: alerts fired at 3:13 PM PST, a few minutes before customer impact began at 3:16 PM, and the root cause was identified at 3:16 PM.

   Remediation

   • Scaled clusters down to reduce the total Kubernetes API load
   • Blocked network access to the Kubernetes admin APIs so no new expensive requests arrived
   • Scaled up the Kubernetes API servers
   • Removed the telemetry service once enough control was back
   • Moved traffic from impacted clusters to healthy ones
   • Intervened manually in clusters where simultaneous resource downloads saturated resource limits

   Action items

   • Put every infrastructure configuration change through a phased rollout with continuous monitoring of both the service workloads and the clusters, including the Kubernetes control plane
   • Run fault injection tests in which the data plane runs without the control plane for longer, and tests that roll out bad changes on purpose to check detection and rollback
   • Build break-glass mechanisms so engineers can reach the Kubernetes API servers in any circumstances
   • Decouple the Kubernetes data plane from the control plane so that service discovery for critical workloads does not depend on the control plane
   • Speed up recovery with better caching and dynamic rate limiters for resources needed at cluster startup, and regular drills that rapidly replace an entire cluster

   Lessons

   Several systems and processes failed at once and interacted in unexpected ways: tests did not catch the change's effect on the Kubernetes control plane, DNS caching put a delay between the change and the failures, and being locked out of the control plane made remediation very slow. Because service discovery used Kubernetes DNS, the control plane was carrying load for product traffic even though the data plane was meant to be independent of it.

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5. 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

   Symptoms

   From 10:15 am PT on 25 November 2024 a large share of both API and ChatGPT traffic failed with timeouts and 503 errors.

   High error rateHigh latencyControl plane unresponsive

   Trigger

   A global change to Kubernetes namespace labels caused the networking layer to recompute metadata. The change had rolled out to the small clusters without problems.

   Root cause

   Configuration change

   Component

   Kubernetes API server

   Contributing factor

   Excessive blast radiusLimited debug access

   Remediation

   • moved workloads out of the impacted clusters by hand
   • with the cloud provider, scaled up the number of control plane nodes while scaling down the number of data plane nodes, which let the control planes recover

   Action items

   • Lock namespace changes so this incident cannot recur
   • Freeze certain types of infrastructure deploys
   • Allowlist identities to prevent a recurrence of this class of incidents
   • Improve the GPU load balancing logic so traffic is re-routed automatically and more effectively when possible
   • Improve change management for fleet-wide infrastructure changes

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