Cases5 cases

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1. IL-0110 A Grafana Agent pod's high memory use and crash-looping Hangfire pods drove a Kubernetes node into system OOM and NotReady, twice in one day

   DFDS2024

   Symptoms

   At 10:01 UTC on 2024-03-13 a Kubernetes node entered NotReady state, with CPU requests at 78% and memory requests at 82%. An alert fired in Slack at 10:03 and was picked up at 10:05. An attempt to SSH into the node at 10:13 failed because it was unresponsive; it started responding again at 10:19.

   Node NotReadyContainer crash loopOOMKilledMonitoring outage

   Trigger

   Pods of a dev container that used Hangfire to trigger jobs failed with OOM and crash-looped on a node where a Grafana Agent pod was already using a lot of memory.

   Root cause

   Capacity exhaustion

   Component

   Telemetry agentContainer memory limitApplication database

   Contributing factor

   Excessive blast radiusNo resource requests or limitsHarmful manual actionMonitoring blind spot

   Detection

   A Slack alert fired two minutes after the node went NotReady and was picked up two minutes later; the second node's NotReady at 15:03 also raised a Slack alert.

   Remediation

   • marked the EC2 instance unhealthy so a new node started
   • cordoned and force-drained the NotReady node and terminated its EC2 instance
   • removed the new LimitRange from the Grafana Agent namespace and restarted the Grafana Agent pod
   • scaled the dev container to 0 replicas, after which EC2 network traffic returned to normal
   • after the second NotReady, scaled the dev container to 0 replicas again and added a new node
   • emailed the team that owns the dev container, which confirmed it was working on a fix

   Action items

   • Move grafana-agent to the monitoring node group
   • Add alerts for when bandwidth across the cluster reaches a certain threshold
   • Investigate whether memory limits can be set on the grafana-agent Helm chart
   • Investigate grafana-agent memory usage
   • Ask Grafana support whether grafana-agent should use a PVC
   • Consider pushing node logs to Loki with limited retention
   • Create a wiki page with common metrics and log queries to check when investigating issues with Kubernetes nodes

   Lessons

   Dev workloads mixed with production let one crash-looping dev container take down nodes that production also used, and a monitoring agent outside its dedicated node group added to the memory pressure. Scaling the suspect container back up before its owners had fixed it brought the failure back on the replacement node. The team also noted that action items from earlier post-mortems need follow-up, and that knowledge of useful CloudWatch metrics had not been shared, which made the diagnosis harder.

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2. 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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3. 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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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-0108 An Alcide admission controller applied to the production cluster during a workshop made create and update requests on Deployments time out

   DFDS2020

   Symptoms

   At 14:41 CET on 4 November 2020 users reported timeouts when deploying to Hellman, the production Kubernetes cluster. The timeouts were confirmed at 15:04.

   Deploys failingControl plane lag

   Trigger

   During an Alcide workshop that began at 13:00 CET, an Alcide admission controller was applied to the production cluster at 13:13 in the belief that it would not disrupt anything.

   Root cause

   Configuration change

   Component

   Admission webhookKubernetes API server

   Contributing factor

   No configuration testsUnverified assumptionMonitoring blind spot

   Detection

   Users reported timeouts when deploying to the Hellman cluster at 14:41 CET; the timeouts were verified at 15:04.

   Remediation

   • toggled the Alcide admission controller to verify that it caused the timeouts
   • permanently deleted the Alcide admission controller

   Action items

   • Monitor Kubernetes deployments for timeouts
   • Monitor 5xx status codes from the Kubernetes API server

   Lessons

   New components are applied in sandbox clusters, not in production. The team needs enough Alcide knowledge to maintain the component until it is fully deprecated.

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