Cases4 cases

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1. 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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2. IL-0027 All CoreDNS pods landed on one node, the node ran out of memory, and DNS for the whole service went down

   Backpackr2025

   Symptoms

   Services on the production Amazon EKS cluster behind the idus marketplace threw intermittent errors whose cause was hard to pin down. Calls to external services such as RDS and Redis failed now and then, and whenever DNS traffic spiked, domain lookups answered slowly or failed outright.

   DNS resolution failuresIntermittent connection failuresHigh latencyOOMKilledService outage

   Trigger

   All CoreDNS pods were scheduled onto the same node, and that node's memory usage spiked until it ran out of memory.

   Root cause

   Capacity exhaustion

   Component

   CoreDNSClient-side DNS resolver and cachekubeletContainer memory limitNode pool

   Contributing factor

   Unreviewed defaultsSingle point of failureNo caching

   Detection

   The write-up does not say how the full outage was noticed. The earlier DNS trouble showed up as intermittent service errors, and investigating failed calls to RDS and Redis led to DNS resolution failures.

   Remediation

   • deployed NodeLocal DNSCache as a DaemonSet in front of CoreDNS
   • added a PodDisruptionBudget (maxUnavailable 1) and topologySpreadConstraints across zones for CoreDNS
   • lowered ndots from 5 to 2 with dnsConfig in the Deployments

   Lessons

   The CoreDNS setup that EKS creates by default (two pods) can be enough for a small or development cluster but becomes a bottleneck in a large production cluster, and DNS is a single point of failure that needs high availability and room to scale. Tuning the CoreDNS cache and buffer size only relieved the symptoms; the real load came from the extra queries that ndots:5 generates for external names. A CoreDNS pod without a memory limit can share a node's fate with everything else on it.

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3. 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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4. IL-0230 kube-proxy sync failures during a Kubernetes upgrade corrupted node iptables, and CircleCI jobs stopped starting

   CircleCI2023

   Symptoms

   On 14 March 2023 at about 18:00 UTC, communication errors rose on one CircleCI service, and pipelines for all customers began to start late until jobs did not run at all. Within an hour the errors had spread to many services and to every function of the application, including the CircleCI UI and API.

   Service outageIntermittent connection failuresDNS resolution failures

   Trigger

   At about 17:40 UTC on 14 March the infrastructure team resumed the upgrade of the main production Kubernetes cluster with a changed approach for some components, after a first attempt on 13 March had been rolled back. The ongoing upgrade left kubelet and kube-proxy at mismatched versions.

   Root cause

   Breaking change in an upgrade

   Component

   kube-proxykubeletCoreDNSClient-side DNS resolver and cache

   Contributing factor

   Partial rolloutIneffective rollbackMonitoring blind spotHarmful manual action

   Detection

   At 18:00 UTC engineers saw communication errors rise on one service, then job processing delays climbing and job queues backing up across several services. The kube-proxy "Sync failed" errors were found only in the analysis after the incident.

   Remediation

   • Restarted every node in the cluster so each node built a fresh iptables ruleset
   • Restarted a separate pool of dependencies so jobs using contexts or the machine executor ran again
   • Added capacity to work through the backlog of jobs
   • Restarted the RabbitMQ nodes to fix a few corrupted queues

   Action items

   • Improve the Kubernetes upgrade process to limit the risk of future upgrades
   • Add metrics and alerts for kube-proxy sync errors
   • Evaluate ways to make the RabbitMQ infrastructure more resilient

   Lessons

   No single trigger caused the incident. Because networking underlies everything in the cluster, Kubernetes upgrades carry inherent risk, and CircleCI's risk mitigation did not hold up when several events interacted.

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