k8s-version-upgrade: scope chain-fail alert to terminal reasons + sync docs
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Refines the new K8sUpgradeChainJobFailed alert from a bare failed-pod count to
the terminal job-condition reasons (BackoffLimitExceeded|DeadlineExceeded). A
phase whose first pod failed but whose retry SUCCEEDED must NOT fire: every
firing alert also halts kured, so a bare-count false-positive would block all
OS node reboots for the Job's 7-day TTL. Verified against kube-state-metrics:
the stuck preflight reports reason="BackoffLimitExceeded"; a Complete job has 0
for the terminal reasons.

Docs updated to match the behaviour change (per the same-commit docs rule):
  - docs/runbooks/k8s-version-upgrade.md — new alert in the gates list; the
    "kill a stuck Job" recovery now leads with retry-on-failure self-heal.
  - docs/architecture/automated-upgrades.md — fourth Upgrade Gates alert;
    retry-on-failure note on the deterministic-naming paragraph.
  - .claude/skills/upgrade-state/SKILL.md — new "chain failed" status, legend
    entry, and drill-down (also copied to the active ~/.claude copy).

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>
This commit is contained in:
Viktor Barzin 2026-06-17 13:10:18 +00:00
parent dfa1a12a86
commit fb638cd8ec
4 changed files with 71 additions and 26 deletions

View file

@ -115,7 +115,8 @@ Pushed by upgrade-step.sh during phase execution; observed by the
- **`K8sVersionSkew`** — distinct kubelet/apiserver `gitVersion` count > 1 for 30m. Catches a half-done rollout.
- **`EtcdPreUpgradeSnapshotMissing`** — `k8s_upgrade_in_flight==1 && k8s_upgrade_snapshot_taken==0` for 10m. Catches preflight Stage 2 failing silently.
- **`K8sUpgradeStalled`** — `k8s_upgrade_in_flight==1 && time()-k8s_upgrade_started_timestamp > 5400` for 5m. Catches a Job in the chain dying without spawning its successor.
- All three alerts ALSO block kured (same `--prometheus-url` halt-on-alert mechanism) so the OS-reboot pipeline can't run on top of a half-done version upgrade.
- **`K8sUpgradeChainJobFailed`** — `kube_job_status_failed{namespace="k8s-upgrade",job_name=~"k8s-upgrade-.*",reason=~"BackoffLimitExceeded|DeadlineExceeded"} > 0` for 15m (warning). Catches a phase Job that **terminally failed before `k8s_upgrade_in_flight` was set** — the preflight gates exit pre-metric, so the two `in_flight`-based alerts above are blind to a failed preflight (this is what hid the 5-day 1.34.9 wedge on 2026-06-12). Reason-scoped to terminal job conditions so a retry-success doesn't false-positive (a bare failed-pod-count would otherwise also block kured for the Job's 7d TTL).
- All four alerts ALSO block kured (same `--prometheus-url` halt-on-alert mechanism) so the OS-reboot pipeline can't run on top of a half-done version upgrade.
### Vault secrets
@ -202,8 +203,18 @@ EOF
```
### Kill a stuck Job (chain halted mid-flight)
The chain stalls if any Job dies without spawning its successor. `K8sUpgradeStalled`
fires after 90 min. Recovery:
A phase Job that dies without spawning its successor halts the chain. Two alerts
surface it: `K8sUpgradeStalled` (a mid-chain Job that died with `in_flight=1`,
after 90 min) and `K8sUpgradeChainJobFailed` (any phase that terminally failed,
after 15 min — including a **preflight** that aborted before `in_flight` was set,
which `K8sUpgradeStalled` cannot see).
**Preflight failures now self-heal** (since 2026-06-17): the detection CronJob and
`spawn_next` delete + re-spawn a terminally-Failed Job instead of skipping it on
name-existence (retry-on-failure), so a transient preflight gate — e.g. a spurious
critical alert like the ttyd web-terminal probe that wedged 1.34.9 for 5 days —
clears on the next daily cycle. A mid-chain phase that keeps failing still needs
manual recovery: fix the root cause, then:
```bash
# 1. Identify the failed Job