fix(longhorn): reclaim orphaned replica directories automatically - #3181
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Longhorn detects replica data left behind on disk and creates an Orphan CR per directory, but orphanResourceAutoDeletion defaults to empty, so it never deletes any of it. Autoscaler scale-downs and worker rolls produce these steadily and a storage node accumulates them until it crosses storage-minimal-available-percentage and its disk flips to DiskPressure. With hard replica anti-affinity and three storage nodes, one node under the threshold means a degraded volume can never rebuild — it sits at ReplicaSchedulingFailure indefinitely instead of recovering. Measured on prod 2026-08-16: 16 orphan directories, 14 on one worker, which sat at 24% available while two CNPG databases stayed stuck at 2 of 3 replicas. Verified against chart 1.12.0: the value renders to orphan-resource-auto-deletion: "replica-data" in the default-settings ConfigMap, and is absent from the render when unset. Fixes #3180
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Parked on a named blocker: The check fails here, but it fails for every open PR that edits a HelmRelease and passes for every one that does not — 4 of 4 versus 2 of 2 on the current open set, including two Renovate image bumps (#3040, #3012). The reported Everything else here is green: 31 of 33 checks pass, and the two failures are this check plus the The change itself is verified against the pinned chart 1.12.0 — the value renders to Holding rather than merging, and deliberately not working around the check: it guards the authorization surface, and the correct fix belongs in #3182. |
…orn value The orphan-reclaim value moves the rendered surface, so the pinned fingerprint no longer matched and the EKS authorization gate failed. Measured base against head: the complete rendered delta is one added line in the longhorn HelmRelease spec.values. Document and grant-bearing object counts are unchanged (177 and 21), and the delta carries no rules, subjects, verbs or apiGroups line. Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
The Longhorn orphan-reclaim value sits in a Because this control exists to make a human/agent look at what moved, I did the base/head comparison rather than pasting the new hash:
Complete rendered delta across the surface — one line, inside an existing object: helm.toolkit.fluxcd.io/v2 HelmRelease longhorn-system/longhorn
+ orphanResourceAutoDeletion: replica-dataThe delta contains no RED/GREEN: the test failed on the unapproved fingerprint before the change and passes after it.
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Code Coverage OverviewLanguages: Go Go / code-coverage/goThe overall coverage in commit a573b41 in the Show a code coverage summary of the most covered files.
Updated |
# Conflicts: # scripts/validate-eks-ci-role-policy/main.go
Both parents had independently re-approved expectedRenderedSurfaceSHA -- this branch for the #3181 Longhorn orphan-reclamation chart value, main for the #2713 gateway-tenant-edit route-kind narrowing -- so neither value describes the merge result and the conflict could not be resolved by picking a side. Both parents' measurement records are retained; the constant carries clean main's digest as an explicitly-labelled UNMEASURED placeholder. The merge result is known not to equal it: the Longhorn HelmRelease is a selected surface document whose content moved. Neither renderer could measure it during this run -- the render accumulates a pinned remote resource and raw.githubusercontent.com returned HTTP 429 on both attempts, an infrastructure failure rather than a measurement. The required job is expected to reject the placeholder and report the actual digest, which the comment directs to be recorded before promotion.
Merged main
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CI is red on an external incident, and the digest measurement is blocked by itBlocker: GitHub CDN rate-limiting of
None of the failures are attributable to this diff:
The same-commit control is what settles it: those four render tests fail with an identical signature on clean main Next run: re-run the failed jobs once the CDN incident clears, then read the digest |
CI diagnosis at What was infrastructure (now cleared by a re-run)Five of the original eleven failures died at
That is platform#3196's unpinned live-fetch pattern, hit during today's rate-limiting window — kustomize What is real, and it is ours
against this branch's It is not the behind-main case, and I checked rather than assumed. The branch is The cause is this PR's own diff. It adds 20 lines to Next stepThis needs a deliberate fingerprint re-approval, not a mechanical constant bump: the delta must be |
…an reclamation The constant carried an explicitly-flagged unmeasured placeholder — clean main's digest — because a CDN 429 had aborted the local render before it produced any surface. The required job rejected it exactly as that note predicted and reported the merge result's actual digest, 489afc66, which is recorded here from run 32070742779. Taken on exact main feaf505 after levelling the branch to behind_by 0, so the value describes the current merge result rather than the older 9a84e92 the placeholder named. Conservation re-verified at that head, as the placeholder required before promotion: the aggregate is the only control that moved — zero per-identity mismatches, zero missing, zero duplicates — and the run reports the same 35 unresolved-substitution notes clean main reports, so surface membership is unchanged. Only one renderer stands behind the digest; the local kubectl is v1.36.1 against an approved v1.36.2 and fails closed. Corroborating that only this branch's delta moves it: the required job reported the identical value at 07ec2b5 before main was merged and at 74676d5 after four further main commits. The delta stays authorization-neutral — one Longhorn chart value under spec.values, with no rules, subjects, verbs, or apiGroups line.
Placeholder discharged — the digest is now measured, not carried throughThe constant here carried an explicitly-flagged unmeasured placeholder (clean main's digest), because a CDN 429 had aborted the local render before it produced any surface. That note predicted the required job would reject it and report the real value. It did. Recorded: Sequence, and why the value is attributable:
Stated plainly: only one renderer stands behind this digest — the approved CI toolchain. The local kubectl is v1.36.1 against an approved v1.36.2, so The delta stays authorization-neutral: one chart value under Next: CI at the new head, then the green-review gate. Not promoting until both are clear. |
main merged #2709, which re-approved expectedRenderedSurfaceSHA for the Dex maintainers-team narrowing, while this branch had re-approved it for the Longhorn orphan-reclamation chart value. Both parents therefore moved the same constant and each described only its own delta, so neither value describes the merge result and the conflict cannot be resolved by picking a side. Resolved by retaining BOTH measurement records — both deltas are present in the merged surface — and leaving the constant as an explicitly-flagged UNMEASURED placeholder at main's value. The required job is expected to reject it and report the merge result's actual digest, which must be recorded before promotion. The superseded #3181 digest 489afc66 is kept in full as a record so the measurement taken at 74676d5 is not lost. Both deltas remain individually measured and individually authorization-neutral or privilege-reducing, and neither moved surface membership; only their aggregate is unmeasured.
Conflict resolved — and the freshly-measured digest is deliberately NOT carried forwardShortly after the digest above was recorded, How it was resolved
What is and is not unmeasured. Both deltas are individually measured and individually authorization-neutral or privilege-reducing, and neither moved surface membership (each measured with 0 per-identity mismatches, 0 missing, 0 duplicates). What is unmeasured is only their aggregate digest, which necessarily differs from both parents because both are selected documents whose content moved.
Next: read the digest the required job reports at |
…erge result The required job rejected the carried-through placeholder and reported the merge result's actual digest. Conservation measured against this branch's own pre-merge rendering: 35 substitution notes both sides, zero resources added, removed or duplicated, and exactly two per-identity fingerprints moved - the dex and oauth2-proxy HelmReleases, which are precisely the two manifests #2709 changes and are already approved on main. Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
Requesting a review at head Evaluation — exercised, not reasoned. The change records the measured authorization-surface digest
The ~35 @coderabbitai review |
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📝 WalkthroughWalkthroughLonghorn now enables automatic deletion of orphaned Possibly related PRs
Important Pre-merge checks failedPlease resolve all errors before merging. Addressing warnings is optional. ❌ Failed checks (2 errors)
✅ Passed checks (3 passed)
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Inline comments:
In `@k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml`:
- Around line 53-72: Add a scoped Kubernetes CronJob alongside the Longhorn
release to detect stale iSCSI node records via iscsiadm and remove each record
only after confirming its corresponding Longhorn volume no longer exists. Reuse
the manifest’s existing namespace, service-account, and security conventions
where applicable, and ensure cleanup is limited to stale Longhorn-related
records. Update the runbook’s relevant iSCSI and replica-data cleanup guidance
so it distinguishes automatic replica-data reclamation from the new iSCSI
remediation.
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Configuration used: Repository YAML (base), Organization UI (inherited)
Review profile: ASSERTIVE
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Run ID: 3ff89bb1-ffc0-43c1-bc51-54c41abf54b8
📒 Files selected for processing (2)
k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yamlscripts/validate-eks-ci-role-policy/main.go
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📓 Path-based instructions (1)
**/*.{yaml,yml}
📄 CodeRabbit inference engine (AGENTS.md)
**/*.{yaml,yml}: Never run a cluster
Put a change in the layer that matches its scope
Files:
k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml
🧠 Learnings (2)
📚 Learning: 2026-07-01T21:13:36.950Z
Learnt from: devantler
Repo: devantler-tech/platform PR: 2359
File: k8s/bases/apps/actual-budget/helm-release.yaml:62-111
Timestamp: 2026-07-01T21:13:36.950Z
Learning: When reviewing Kustomize/Helm YAML in this repo, keep the base vs provider overlay split: `k8s/bases/apps/**` and `k8s/bases/infrastructure/**` should contain each app’s full, environment-agnostic configuration (including base-level postRenderer Kustomize patches such as deployment strategy, topology spread, probes, and env injection). `k8s/providers/{docker,hetzner}/**` should only add small provider-specific deltas (e.g., `interval`, `persistence.size`) via patch files (like `k8s/providers/<provider>/apps/<app>/patches/helm-release-patch.yaml`). If configuration is identical across providers (e.g., OIDC/OAuth env vars where `${domain}` is resolved per cluster via envsubst), it belongs in the base and must not be duplicated into provider overlays.
Applied to files:
k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml
📚 Learning: 2026-08-11T12:41:28.242Z
Learnt from: devantler
Repo: devantler-tech/platform PR: 3082
File: k8s/bases/infrastructure/controllers/coroot/cron-job-cnpg-degraded-alert.yaml:113-120
Timestamp: 2026-08-11T12:41:28.242Z
Learning: When changing behavior in Kubernetes manifests or related documentation, review comments and documentation in YAML/YML and Markdown files for statements describing the previous behavior. Update every stale statement in the same change so the repository’s explanatory text remains consistent with the implementation.
Applied to files:
k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml
🔇 Additional comments (1)
scripts/validate-eks-ci-role-policy/main.go (1)
625-642: LGTM!Also applies to: 680-680, 706-709, 722-727, 742-751, 856-922, 968-1011
Restarting the review loop at the same head Resolution summary: the 🟠 Major finding was valid on its central point — this PR carried @coderabbitai review |
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The previous request hit the incremental wedge ( @coderabbitai full review |
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🧠 Learnings used
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… fixes The comment cited #3180 for the orphan-directory DiskPressure evidence, but #3180 is the stale iSCSI node record blocking engine startups - a different failure mode that this change does not address and that stays open. The evidence described here belongs to #3201. Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
New head Predicted and confirmed: the edit does not move the authorization fingerprint, because YAML @coderabbitai review |
🧩 Analysis chain🏁 Script executed: #!/bin/bash
set -euo pipefail
echo '== PR metadata =='
gh pr view 3181 --repo devantler-tech/platform --json number,headRefOid,baseRefOid,isDraft,mergeStateStatus,title,body,statusCheckRollup \
--jq '{number, headRefOid, baseRefOid, isDraft, mergeStateStatus, title, body, checks: [.statusCheckRollup[] | {name, status, conclusion}]}'
echo
echo '== Changed files =='
gh pr diff 3181 --repo devantler-tech/platform --name-only
echo
echo '== Full PR diff =='
gh pr diff 3181 --repo devantler-tech/platform
echo
echo '== HelmRelease outline =='
ast-grep outline k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml --items all || true
echo
echo '== HelmRelease relevant lines =='
nl -ba k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml | sed -n '45,85p'
echo
echo '== Validator declaration outline =='
ast-grep outline scripts/validate-eks-ci-role-policy/main.go --items all --type function,const,var | sed -n '1,240p'
echo
echo '== Fingerprint records and validation references =='
rg -n -C 6 'expectedRenderedSurfaceSHA|489afc66|8773eaf0|orphanResourceAutoDeletion|validateAuthorization' scripts/validate-eks-ci-role-policy/main.goLength of output: 20118 🏁 Script executed: #!/bin/bash
set -euo pipefail
echo '== Checked-out commit and local diff statistics =='
git rev-parse HEAD
git diff --stat 6c5506fe796d3168b3a55aa90cabd16f11d45d4b..HEAD
git diff --check 6c5506fe796d3168b3a55aa90cabd16f11d45d4b..HEAD
echo
echo '== Current Longhorn HelmRelease range =='
sed -n '42,82p' k8s/providers/hetzner/infrastructure/controllers/longhorn/helm-release.yaml
echo
echo '== Current fingerprint record and use sites =='
rg -n -C 5 'const expectedRenderedSurfaceSHA|expectedRenderedSurfaceSHA\b|ed2767037a88348b22ec8ecfcc8b2081e86b7979dfe3c86d554034980af01fdf|489afc6651045b6643ee40e0098234a873174a8d807690efb0245aaf92f87a4b|8773eaf0015f04f14850c5ef025b81657b0ad8d3aab397d99cf969044c04d7e6' scripts/validate-eks-ci-role-policy/main.go
echo
echo '== Authorization validation function map and digest comparison =='
ast-grep outline scripts/validate-eks-ci-role-policy/main.go --items all --type function --match 'validateAuthorization|validateRendererVersion|render'
rg -n -C 10 'unapproved rendered authorization surface fingerprint|expectedRenderedSurfaceSHA' scripts/validate-eks-ci-role-policy/main.go
echo
echo '== Scope of issue `#3201` =='
gh issue view 3201 --repo devantler-tech/platform --json number,state,title,body,url \
--jq '{number,state,title,body,url}'
echo
echo '== Latest required check state =='
gh pr view 3181 --repo devantler-tech/platform --json headRefOid,mergeStateStatus,statusCheckRollup \
--jq '{headRefOid, mergeStateStatus, checks: [.statusCheckRollup[] | select(.name == "🔐 Validate EKS Authorization" or .name == "🧪 Validate Manifests" or .name == "📊 Code Coverage") | {name,status,conclusion}]}'Length of output: 14761 🤖 web_search executed:
Length of output: 7346
The correction aligns the PR body, the HelmRelease comment, and I used the recorded The required 🧠 Learnings used
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🤖 Generated by the Agentic Engineer
Self-review (fallback — CodeRabbit, Codex and Cursor Bugbot unavailable)
Reviewed commit: a573b417103f47007150618aa29ff0c0752b72dd
Per-lane state at this head:
| Lane | State |
|---|---|
| CodeRabbit | rate-limited at this head — requested at 22:47Z, head status went to Review rate limited. Earlier at 8f9c86b6 it did deliver a real review (below); a same-head restart then hit the incremental wedge (Action not completed — Already reviewed) and the full review escape was accepted at 22:41:53Z and immediately rate-limited at 22:41:57Z |
| Codex | usage-limited — account-level, confirmed 22:25:44Z; no retry window, maintainer-only to lift |
| Cursor Bugbot | usage limit — account-level; no retry window, maintainer-only to lift |
CodeRabbit's own review of this change is part of the record
This is not a lane that never looked. At 8f9c86b6 CodeRabbit delivered a substantive review and raised one 🟠 Major finding, which was valid and is accepted: the PR carried Fixes #3180 while doing nothing about the stale iSCSI node records #3180 actually asks for, so merging would have auto-closed a live production failure mode. Resolved by filing #3201 for what this change genuinely fixes, repointing the PR, and leaving #3180 open with its remaining work recorded. CodeRabbit acknowledged the resolution addresses the finding. This head adds only the follow-on fix to the same defect one level down — a chart comment still citing #3180 for evidence belonging to #3201.
Correctness of the digest, which is the risky half
The constant is not accepted on the strength of CI agreeing with it; it was predicted and then checked:
- Conservation measured against this branch's own pre-merge rendering (
74676d5a, run 32071082835) rather than againstmain— the control that isolates what the merge brought in, since both renderings already contain this branch's Longhorn delta. Both report 35 unresolved-substitution notes, all distinct, 0 added, 0 removed, 0 duplicated: surface membership unchanged. - Exactly two per-identity fingerprints moved — the
dex/dexandoauth2-proxy/oauth2-proxyHelmReleases. Those are precisely the two manifests #2709 changes; it touches those two files and this validator, the last of which is not in the surface. A falsifiable prediction: anything else carried in would have moved a third identity, and none did. main6c5506fecontains #2709 and passes the required job against its own digest, so both moved documents are already approved there. The aggregate is the only control this merge changes.- The comment-only edit at this head was predicted not to move the fingerprint, because YAML comments are stripped from the render — evidenced by this PR's own ledger recording the rendered delta as one line although the same commit added a six-line comment block. Confirmed: the required job passes here with the constant unchanged.
- Post-edit assertions: exactly one
constdeclaration; both superseded digests (489afc66,8773eaf0) retained in full rather than as prefixes; the constant byte-equals CI's reported value under an empty-guard with a negative control.
One caught slip worth recording: replacing the const line removed the only full 64-character copy of main's 8773eaf0, leaving an 8-character prefix in prose. Restored. A prefix-only assertion would have passed straight over that loss.
The destructive-setting question, analysed rather than assumed
orphanResourceAutoDeletion: replica-data enables automatic deletion of data, so it deserves a direct answer rather than a shrug. It is not in tension with this repo's two-stage persistence-retirement rule: that rule protects PVCs, HelmReleases and Namespaces from Flux pruning, whereas a Longhorn orphan is by definition replica data on disk with no owning replica resource — there is no live PVC behind it to retire. The narrower replica-data type is deliberate: orphaned instances are runtime processes and are not swept. The failure this prevents is itself a data-availability risk — a storage node at 24% free and DiskPressure left two databases unable to rebuild a third replica at all.
Independence
This is my own PR, so this round is a self-review. It is posted because all three lanes are demonstrably not delivering at this head, not because one was slow — and CodeRabbit's real review of the substantive change, plus its finding and my acceptance of it, sits in this PR's history rather than being replaced by this round.
Verdict: no P0/P1 findings.
1 participant
Why
Longhorn spots replica data left behind on disk and files an Orphan record for each directory — but it never deletes any of it, because the auto-deletion setting ships empty. Every autoscaler scale-down and worker roll adds more, so a storage node slowly fills with dead data until it drops below the free-space threshold and stops accepting replicas.
That is what just happened on prod: one worker was holding 14 orphaned directories, sat at 24% free, and went
DiskPressure. Because replicas must live on distinct nodes and there are only three storage nodes, two databases were then unable to rebuild their third replica at all — stuck degraded indefinitely rather than recovering on their own.What
Turns on automatic reclamation of orphaned replica data, so this space comes back without anyone noticing it was gone.
Verified against the pinned chart: the setting reaches Longhorn's rendered configuration when set, and is absent when not — so this genuinely changes behaviour rather than being a silent no-op. Orphaned instances are deliberately left alone; only disk-consuming replica data is swept.
Fixes #3201