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jakman85 52398d4426 merge: Longhorn alerting measured the wrong things, three ways
gate / gate (push) Has been cancelled
gate / conformance (push) Has been cancelled
(1) LonghornVolumeCapacityHigh alarmed on ALLOCATION while calling itself a
capacity alarm. Prometheus's TSDB volume read 0.973 while the kubelet saw the
same filesystem at 0.208, because 37.73 GiB of it is a Longhorn SYSTEM
snapshot — the kind taken for the full replica rebuild that prod-1's drive
replacement forced — growing +152 MB/h while the filesystem stayed flat. The
rule was therefore unclearable by design, i.e. permanently firing. Deleted as
redundant, shown rather than asserted: 23 of 24 volumes fall under the
kubelet-based filling rules, and the 24th is volumeMode Block, which the
deleted rule was not covering either.

(2) LonghornVolumeDegraded and LonghornVolumeFaulted could not fire even with
the scrape working. longhorn_volume_robustness on 1.12.1 is ONE-HOT over a
state label with values 0/1, not the 0-3 enum the rules and their comment
assumed, so a faulted volume would have alerted nobody. This survived the
scrape fix landing hours earlier.

(3) LonghornNodeStorageHigh was wrong twice: its 0.85 threshold sat above the
75% at which storage-minimal-available-percentage=25 already removes a disk
from the scheduling pool, and longhorn_node_storage_usage_bytes SUMS a node's
disks, so one full disk hid behind a half-empty sibling. Replaced with
per-disk LonghornDiskAllocationHigh (>0.70) and LonghornDiskUnschedulable,
the latter reading Longhorn's own verdict instead of re-deriving a formula
from three settings no metric exports.

Baseline green with 11/11 mutations red. retentionSize 45GiB of 50Gi and
discard/TRIM are both REPORTED with recommendations, not changed: TRIM would
not have helped here, since remove-snapshots-during-filesystem-trim is false
and the 37.7 GiB is a snapshot.

# Conflicts:
#	DECISIONS-LOG.md
2026-09-13 17:23:37 -05:00
jakman85andClaude Opus 5 4687521d65 fix(monitoring): delete the Longhorn rule that measured allocation and called it capacity
LonghornVolumeCapacityHigh went pending within minutes of the Longhorn scrape
landing today. Re-measured on prod: it read 0.9731 on the Prometheus TSDB volume
(actual_size 52243681280 / capacity 53687091200) while the kubelet reported the
SAME filesystem 20.8% used. actual_size is head + pinned snapshots, and one
user_created=false system snapshot from prod-1's replica rebuild holds 40510484480
bytes (37.7 GiB) of it; Longhorn returns no freed blocks without discard/TRIM, and
retentionSize 45GiB on a 50Gi volume targets 90% by design. The ratio is pinned
near 1.0 and cannot fall back under 0.85 — a permanently-firing alert, the same
shape as CNPGNoRecoverabilityPoint.

DELETED, not re-thresholded. Raising the threshold would tune away a true
statement about allocation. Redundancy proven, not asserted: of 24 Longhorn
volumes on prod, 23 appear in kubelet_volume_stats_inodes > 0 and so fall inside
MonitoringVolumeFillingUp (namespace="monitoring") or PersistentVolumeFillingUp /
PersistentVolumeAlmostFull. The 24th is unifi/unifi-rootdisk, volumeMode Block —
no filesystem for anyone to measure, and the deleted rule was not covering it
either.

AND A SECOND INERTNESS the scrape did not fix. longhorn_volume_robustness on
longhorn 1.12.1 is one-hot over a `state` label with values 0/1, not the 0-3 enum
the rules assumed:
  count(longhorn_volume_robustness)                  => 96  (24 volumes x 4 states)
  count by (state) (longhorn_volume_robustness == 1) => {state="healthy"} 24
  count(longhorn_volume_robustness == 2)             => (empty)
  count(longhorn_volume_robustness == 3)             => (empty)
So a FAULTED volume would still have alerted nobody. Re-keyed to the label; the
"44 series / 72 unknown(0, detached)" note in platform/longhorn/helmrelease.yaml
was the same misreading and is corrected in place.

The allocation question moved to where allocation is a budget. LonghornNodeStorageHigh
fired at 0.85, but storage-minimal-available-percentage is 25 on this cluster, so a
disk leaves the scheduling pool at 75% used — the old threshold could only fire
after scheduling had already been refused. Replaced by:
  LonghornDiskAllocationHigh  (longhorn_disk_usage_bytes / longhorn_disk_capacity_bytes) > 0.70, 30m
  LonghornDiskUnschedulable   longhorn_disk_status{condition="schedulable"} == 0, 15m
Per DISK, not per node: longhorn_node_storage_usage_bytes sums a node's disks, so
one full disk could hide behind a half-empty sibling. Measured prod usage
0.2254 / 0.2306 / 0.2369 on prod-1/2/3.

PROVEN NEITHER PERMANENTLY FIRING NOR INERT. platform/monitoring/tests/longhorn.test.yaml
adds 6 cases pinning every rule quiet on today's measured prod state and firing on
a constructed bad state, with every `for:` asserted, plus regression assertions that
the old `== 2`/`== 3` forms match nothing and that per-disk 0.72 is visible where the
node-summed 0.475 is not. Mutation-checked 11 ways; each turns the suite RED. Live on
prod: all four new expressions return empty, while the sum of their selector
cardinalities is 54. The L0 UNTESTED_ALERTS register shrinks by seven (7/56 -> 14/58
alert rules unit-tested), which also brings MonitoringVolumeFillingUp,
PersistentVolumeFillingUp and PersistentVolumeAlmostFull under test since the
redundancy claim rests on them.

REPORTED, NOT CHANGED (DECISIONS-LOG, owner decisions): retentionSize 45GiB on a
50Gi volume is too tight — recommend 36GiB, with reasoning; and discard/TRIM on the
longhorn StorageClass is feasible but not advisable now — remove-snapshots-during-
filesystem-trim reads false on prod, so trim would not have reclaimed the 37.7 GiB
anyway, and continuous discard on nodes where the etcd WAL shares the spindle points
at this cluster's known failure mode.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 17:19:03 -05:00
jakman85andClaude Opus 5 cf7d97e546 fix(obs): twelve app SLI rules read a signal that exists; kill the dead ServiceMonitors
Twelve `<app>-down` SLI rules were STRUCTURALLY INERT. Each read `up{job="<app>"} == 0`,
and the ServiceMonitor rendered beside it named `endpoints[].port: metrics` — a port NO
rendered app Service defined. Every monitor discovered ZERO targets, so no `up{job="<app>"}`
series existed and the rule could not fire. Verified on prod before this change:
`count by (job) (up)` listed 24 jobs and not one of the twelve appeared; `up{job="plex"}`
and `up{job="gitea"}` both returned nothing. `PrometheusTargetsMissing` could not see it
either — a target that was never discovered has no `up` series to be 0.

THE PORT NAME WAS NEVER THE MISSING PIECE. Ground truth per app: Plex, Pi-hole, Jackett,
qBittorrent, Sonarr, Radarr, Seerr, Semaphore and Nextcloud export NO Prometheus metrics
without a separate exporter sidecar; Gitea can but only with app.ini metrics enabled;
Keycloak does, on the operator's management port, already scraped by
platform/keycloak/servicemonitor.yaml; vm-demo is a KubeVirt VM with no Service at all, so
its monitor selected nothing whatsoever. `metrics: true` was asserting a fact none of them
had. There was also a THIRD layer of inertness nobody had hit yet: every app namespace ships
default-deny with `ingress: []` and the renderer emitted no monitoring allow, so even a
correct port would have been dropped by policy — while renderer-contract.md claimed the
baseline carried such an allow.

FIXED IN THE GENERATOR, not in twelve rendered files:
  * `slis: [up]` now renders a `<app>-down` alert against kube-state-metrics readiness of the
    service's own workload object —
    `kube_deployment_status_replicas_available{namespace,deployment} == 0 or absent(...)`,
    `kube_statefulset_status_replicas_ready` for a StatefulSet, and
    `absent(kubevirt_vmi_info{namespace,name,phase="running"})` for a VM. The same idiom
    KeycloakDown has used since it was fixed. kube-state-metrics IS scraped, so this needs no
    exporter and no new target. The `or absent(...)` half is load-bearing: the signal
    DISAPPEARING now fires the alert instead of silencing it.
  * schema 1.6.0 adds `observability.metricsEndpoint` — WHERE metrics are served. A
    ServiceMonitor is rendered ONLY from it, and it renders all three halves of a working
    scrape together: the named Service port, the monitor endpoint, and the
    monitoring-namespace CiliumNetworkPolicy allow. No catalog entry declares one, so twelve
    dead ServiceMonitors are gone. `metrics: true` keeps meaning logs-to-Loki plus
    kube-state-metrics liveness.
  * schema 1.6.0 also adds `observability.livenessWorkload`, and catalog/keycloak.yaml uses
    it. Keycloak's server is a StatefulSet run by the operator; the default Deployment shape
    would have made its `absent()` half fire FOREVER — the other failure mode this repo has
    shipped.
  * renderer selftest gains cases 9/9a/9b/9c: no metricsEndpoint => no monitor; the up SLI
    must not read `up{job=...}`; endpoint port must exist on the Service; the metrics port
    must NOT reach the Gateway allow; an unknown livenessWorkload.kind is REFUSED.

PROOF, both directions, for all twelve (apps/wave-{0,1,2}/tests/app-slis.test.yaml, run by
platform/monitoring/tests/run.sh over the RENDERED manifests):
  * quiet on the healthy state; firing on no-ready-replica; firing when the series is ABSENT;
    the VM asserted both gone and in a non-running phase; per-app isolation asserted, and
    keycloak asserted un-maskable by its neighbours (keycloak-operator Deployment,
    keycloak-db StatefulSet ready in the same namespace).
  * mutation-checked: six mutations, each turning its suite red — reverting plex to
    `up{job=...} == 0`; dropping seerr's `absent()` half; pointing keycloak at a Deployment;
    capitalising the VMI phase to `Running`; widening keycloak's matcher to the namespace;
    inverting plex's `== 0` to `!= 0`. Control run green.
  * live on prod with `promtool query instant`: all ten deployed app Deployments export
    `kube_deployment_status_replicas_available`,
    `kube_statefulset_status_replicas_ready{namespace="keycloak",statefulset="keycloak"}` = 2,
    `kubevirt_vmi_info` present with a lowercase `phase="running"`; and evaluating the twelve
    SHIPPED expressions returns no series for eleven (quiet, not permanently firing). The
    twelfth is vm-demo, which is not in apps/wave-0/kustomization.yaml and so is not deployed
    — its rule is not applied either.

DELETION WAS NOT THE ANSWER, and the evidence is recorded rather than assumed:
kube-prometheus-stack's `kubernetes-apps` group IS live on prod (17 rules, KubePodNotReady /
KubeDeploymentReplicasMismatch among them), so app pods are not unmonitored — but that is a
generic warning keyed to a namespace, not the per-service CRITICAL SLI R-OBS-01 declares.
platform/monitoring/alerts.yaml carries no generic app-readiness rule at all.

GUARD SO IT CANNOT RECUR SILENTLY: new whole-repo L0 invariant
conformance/tests/l0-static/servicemonitor-ports-resolve. It walks the MONITORS, not the
alerts, so it needs no `up{job=...}` rule to reach one, and resolves each endpoint by SELECTOR
across the whole tree rather than by same-file adjacency. Fixing the alerts DELETED the only
thing that made the broken monitors visible to the sibling check, which is exactly why this
axis needed its own home. It declares `conformance.home.k3s/scope: whole-repo` and adds no
ci/l0.sh stage. Proven to FAIL on the pre-fix tree: 15 failures — eleven port disagreements,
vm-demo's monitor matching no Service at all, and the three generator/contract assertions —
and to pass after. Its resolver is additionally proven on in-check fixtures (agreeing pair
accepted, disagreeing pair rejected, target-less endpoint rejected), because after the fix
there are zero in-repo monitors left for it to judge and a guard whose only evidence is
"nothing failed" cannot be told apart from one that stopped working. It also asserts
r_servicemonitor does not HARDCODE a port name — the mechanism by which one edit gave twelve
services the same wrong one.

Also fixed, found on the way:
  * platform/monitoring/tests/run.sh discovered the SUITE convention only inside
    platform/monitoring/tests/ while documenting it as general — a suite added anywhere else
    was never run and still looked like coverage. Now discovered tree-wide; a misplaced
    *.test.yaml fails loudly instead of vanishing.
  * KNOWN_UNWIRED_JOBS in alert-metrics-have-scrape-targets is now EMPTY, and the twelve
    apps/* entries in alert-rules-unit-tested's UNTESTED_FILES are gone — both because the
    gaps were CLOSED, not waived. Both registers are shrink-only and a stale entry fails.
  * renderer-contract.md claimed the default-deny baseline carried a standing monitoring
    scrape allow. It never did; the claim is corrected and the allow is now real, per declared
    metrics endpoint and scoped to that one port.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 17:11:30 -05:00
jakman85andClaude Opus 5 8b36242643 fix(monitoring): kube-state-metrics was OOMKilled 91 times — 13 rules went intermittent
Working set measured at 111 MiB with a 6h peak of 123.3 MiB against a 128Mi
limit, so it died on every spike — exit 137, roughly every 11 minutes, 91
restarts in 16h.

The consequence is worse than the restarts. Thirteen alert rules read kube_*
series, so each kill made them intermittently unable to fire, which is the
quiet version of the inert-alert class found elsewhere today; KubePodNotReady
and KubeDeploymentReplicasMismatch were both sitting pending on it.

Self-inflicted: enabling customResourceState for the Velero Schedule metrics
earlier today added a CRD informer plus the mandatory CRD list/watch, and
that marginal cost crossed a limit already sitting about 4 MiB above the
working set. Raised to 384Mi, roughly 3x the observed peak, which costs
nothing on nodes reporting 18.7-22.3 GiB available.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 16:32:28 -05:00
jakman85andClaude Opus 5 a92fa11701 feat(monitoring): scrape Longhorn + cert-manager — 8 alerts were structurally inert
An alert rule whose metric is never scraped is not a broken alert, it is an ABSENT
alert that reads as a present one. `longhorn_volume_robustness == 2` over a TSDB
with no longhorn_* series returns no vector: permanently quiet, permanently
"healthy", indistinguishable from a correct rule. It survives review (the PromQL is
right), it survives `promtool test rules` (the unit test supplies the series
itself), and it appears on no dashboard.

VERIFIED ABSENT ON PROD before this change (re-verified 2026-09-13 21:0xZ, ~15h
after the first audit, because a stale reading is not evidence):

  count(longhorn_volume_robustness)                      => (empty)   4 rules inert
  count({__name__=~"certmanager.*"})                     => (empty)   3 rules inert
  count(hubble_drop_total) / {__name__=~"cilium.*"}      => (empty)   1 rule inert
  count by (job) (up)                                    => 20 jobs, none of them
                                                            Longhorn, cert-manager,
                                                            Cilium or Hubble

Consequence: storage health was unmonitored on the cluster whose prod-1 had just
had a failing SSD, and TLS expiry was unmonitored with the live `wildcard-home`
wildcard 89 days from expiry on an ACME DNS-01 renewal that can fail silently.

WHAT THIS CHANGES

  * platform/longhorn: `metrics.serviceMonitor.enabled: true` (the supported chart
    way — rendering longhorn 1.12.1 emits exactly 1 ServiceMonitor with the flag and
    0 without), plus networkpolicy-metrics.yaml. The NetworkPolicy is LOAD-BEARING,
    not belt-and-braces: measured with the monitor applied and no allowance, all 3
    targets were DISCOVERED and every scrape failed `context deadline exceeded`
    after 10.0s — a drop, not a refusal — while curling the endpoint from inside
    the manager pod returned 200 in 0.031s. Longhorn 1.12.1 ships 6 NetworkPolicies
    of its own, guarded on `networkPolicies.restrictInternalTraffic` (default TRUE)
    and NOT on `networkPolicies.enabled`, so they are effectively unconditional and
    the manager policy admits only same-namespace Longhorn components. The one-line
    alternative (restrictInternalTraffic: false) was rejected: it deletes the
    internal-traffic restriction across all six components to open one port to one
    namespace, trading an R-SEC-02 control for an observability one when the two do
    not conflict. This policy is Ingress-only, ns monitoring -> app=longhorn-manager,
    TCP 9500 only; 9502/9503 (webhook, recovery backend) stay closed.

  * platform/cert-manager: `prometheus.servicemonitor.enabled: true`. Chart default
    already serves 9402; only the monitor was missing. No NetworkPolicy needed —
    neither ns cert-manager nor ns monitoring carries one. NOT paired with
    prometheus.podmonitor.enabled: the chart calls `fail` if both are set.

  * platform/kubevirt: KubeVirtVMLaunchFailing queried
    `kubevirt_vmi_phase_count{phase="Failed"}`, which DOES NOT EXIST on the deployed
    KubeVirt — a different flavour of the same defect, with the scrape target up and
    healthy. Prod has only `kubevirt_vmi_info` and `kubevirt_vmi_number_of_outdated`;
    the only phase-bearing names are the phase_transition_time histograms. Corrected
    to `kubevirt_vmi_info{phase="failed"}` — LOWERCASE, because KubeVirt lowercases
    the value (observed `phase="running"` for the unifi VMI) and a capital-F matcher
    would select nothing and be exactly as inert.

PROVEN, NOT ASSERTED. The rendered ServiceMonitors were applied to prod by hand and
the metrics observed to land, then REMOVED again so the merge's Helm upgrade creates
and owns them rather than colliding with an unowned object:

  count(up{job="longhorn-backend"})        => 3        (all three managers, up==1)
  count({__name__=~"longhorn.*"})          => 8717     (was empty)
  count(longhorn_volume_robustness)        => 44
  up{namespace="cert-manager"}             => 3 targets, all 1
  count({__name__=~"certmanager.*"})       => 104      (was empty)
  wildcard-home days to expiry             => 89.2, ready_status{condition="True"}=1

All 58 alert rules in the repo were then evaluated against prod one by one: every
one returns a result without error, and exactly ONE fires.

TRIAGE OF THE ONE NEWLY-FIRING ALERT — A TRUE POSITIVE, NOT TUNED AWAY.
LonghornVolumeCapacityHigh on the Prometheus TSDB volume:
`longhorn_volume_actual_size_bytes / longhorn_volume_capacity_bytes` = 0.971
(48.6 GiB allocated of 50 GiB) while the kubelet's view of the same filesystem is
only 20.4% used. Longhorn is not reclaiming freed blocks, so ~48.6 GiB x 3 replicas
is committed for ~10 GiB of real data. On a cluster whose failure mode is disk
pressure and whose etcd WAL shares a spindle with Longhorn, that is worth knowing
and was invisible until now. The threshold is left alone; the follow-up is
filesystem trim, not a bigger number.

THE GUARD (conformance/tests/l0-static/alert-metrics-have-scrape-targets)

Whole-repo L0 invariant, 118 assertions. It crosses from each alert to the scrape
config that makes its metric exist: every metric name is claimed by exactly one
declared owner, and each owner's enabling declaration is re-proven against the
working tree on every gate run, including the negative conditions that defeat an
enablement without deleting it. `up{job="X"}` is audited on its own axis, because
`up` always exists: where this repo authors a Service and a ServiceMonitor in the
same file, the monitor's endpoint port must be a port that Service defines.

It DECLARES conformance.home.k3s/scope: "whole-repo" and adds NO ci/l0.sh stage —
the whole-repo-invariants-wired meta-test fails the gate if one reappears.

PROVEN ABLE TO FAIL, five ways, each reverted:
  1. an alert on a fabricated metric          -> FAIL "claimed by NO entry"
  2. longhorn metrics.serviceMonitor removed  -> FAIL "no longer matches"
  3. networkpolicy-metrics.yaml unwired       -> FAIL "the monitor alone is NOT enough"
  4. cert-manager podmonitor also enabled     -> FAIL "FORBIDDEN pattern"
  5. a register entry made stale / removed    -> FAIL in both directions

TWO SHRINK-ONLY REGISTERS, because a blanket fail would make the gate red until
work that is not this change lands, and a disabled gate protects nothing:

  * KNOWN_UNWIRED_METRICS (1): hubble_drop_total. See below.
  * KNOWN_UNWIRED_JOBS (12): every apps/* `<app>-down` SLI rule is ALSO inert, and
    this was found by the re-audit, not previously known. The rendered
    ServiceMonitors name `port: metrics` and NOT ONE of the twelve app Services
    defines a port of that name (zero occurrences of `name: metrics` across all
    twelve manifests); prod confirms none of the twelve jobs appears in `up`. This
    is the nastiest variant of the class: `up` exists in abundance so nothing looks
    wrong, and PrometheusTargetsMissing cannot see it either, because a target that
    was never discovered has no up series to be 0. Closing it needs an exporter per
    app (Plex, Pi-hole, Jackett, qBittorrent, Sonarr, Radarr, Seerr speak no
    Prometheus) — except keycloak, where the live jobs are keycloak-service /
    keycloak-discovery and the rule is a rename away from being live.

NOT DONE HERE, DELIBERATELY: Hubble. hubble.metrics.enabled RECONFIGURES THE CNI —
it opens 9965 on every cilium-agent and rolls the DaemonSet across all three nodes,
serialised by this repo's own maxUnavailable: 1 (set after the 2026-09-01
k8sServiceHost outage, where a CNI roll deadlocked 2 of 3 agents). It also needs a
matching edit to roles/cilium/templates/cilium-values.yaml.j2 in the same commit,
because platform/cilium/helmrelease.yaml carries a [parity] contract against it and
a rebuilt node would otherwise bootstrap a CNI config that disagrees with the
reconciled one. Recommended as its own change on the cilium Kustomization, with the
Ansible parity edit, a narrow labelsContext, and a one-node canary — not smuggled in
here.

ALSO FOUND, NOT FIXED HERE: kube-state-metrics is OOMKilled every ~10 minutes on
prod (90 restarts in 16h against a 128Mi limit) while its logs show the
custom-resource-state factory reloading every 3 seconds. Thirteen alert rules read
kube_* metrics, so those rules are INTERMITTENTLY inert — the same defect class,
arriving through a crashloop rather than a missing monitor. Needs its own change.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 16:21:44 -05:00
jakman85andClaude Opus 5 a79693d3bd feat(monitoring): scrape the Flux controllers — five gotk_* alerts were inert
gate / gate (push) Has been cancelled
gate / conformance (push) Has been cancelled
kube-prometheus-stack does not scrape flux-system: the controllers are
bootstrapped, expose no Service, and no chart value covers them. So every
gotk_* alert rule in platform/monitoring/alerts.yaml could never fire —
verified on prod, count({__name__=~"gotk.*"}) returned nothing. A repo whose
entire delivery model is Flux had no alerting on reconciliation failing, a
Kustomization erroring, or a resource left suspended.

Proven live before landing: with this PodMonitor applied, gotk_suspend_status
returns 39 series and gotk_reconcile_condition 117, and FluxResourceSuspended
actually fired on a deliberate test suspension — evidence the rule is live,
not merely present.

Extracted from the wider inert-alert audit on
fix/scrape-targets-for-inert-alerts, which stalled unfinished. This is the
self-contained, verified half; Longhorn and cert-manager metrics are still
ABSENT and their alerts remain inert. It also adopts the object into git: it
existed on prod only as kubectl-client-side-apply, so a rebuild would have
lost it.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 08:53:21 -05:00
jakman85andClaude Opus 5 78d0f1b0f6 feat(ci): promtool in the pinned toolchain, one alert-rule harness, and the gaps declared
The CNPG alert unit tests (324 lines, mutation-checked) were run by NOTHING. promtool was
not in the baked toolchain, no gate stage evaluated any *.promtool-test.yaml, and the only
runner `curl | tar -xz`'d a promtool release from GitHub at TEST-RUN time if one was
missing. Hours later a second, independent harness landed for the Velero rules
(platform/monitoring/tests/) with its own fallback — a `podman run` of
quay.io/prometheus/prometheus. So the repo had two harnesses, two acquisition paths, and
coverage that looked present and was enforced nowhere: the exact failure mode that had just
produced a permanently-firing CNPG alert and a structurally inert Velero alert.

PROMTOOL IS NOW PINNED LIKE EVERY OTHER TOOL. PROMTOOL_VERSION=3.14.0 in
infra/devcontainer/versions.env and ci/versions.env (the two stay in lockstep, per the
repo's rule), baked by the Containerfile from the prometheus release tarball (promtool ships
inside it), recorded in /etc/dev-toolchain-versions, passed by dev.sh, and installed for the
l0 stage by .gitea/workflows/scripts/install-tools.sh so the CI runner is not permanently
SKIPPED. The pin is not free-floating: promtool IS the rule engine, so it tracks the
Prometheus prod actually runs — verified against the live cluster, not assumed:

    kubectl --context k3s-prod get prometheus -n monitoring -o jsonpath='{.items[*].spec.version}'
      -> v3.14.0-distroless   (image quay.io/prometheus/prometheus:v3.14.0-distroless)

ONE HARNESS. platform/cnpg/run-alert-tests.sh is folded into
platform/monitoring/tests/run.sh, which now covers every PrometheusRule in the repo that has
tests, via two conventions it discovers automatically: `<manifest>.promtool-test.yaml`
beside its manifest (cnpg), and `<component>/tests/*.test.yaml` over that component's
manifests (monitoring). It writes the flattened rules under whatever name each test file's
own `rule_files:` declares, so no test file needs to know the harness exists, and it
`promtool check rules` first — a rules file that does not parse would make every unit test
pass vacuously by finding no rules at all. The cnpg script's reasoning is preserved: why a
CR must be flattened (`.spec.groups`, never re-typed), and why generated files go to a temp
dir. Its `${BASE_DOMAIN}` substitution is dropped in favour of extract_rules.py's verbatim
placeholders, with the trade-off recorded there — the hazard it guarded against is addressed
by the temp dir, and verbatim leaves one transformation fewer between the shipped rule and
the rule under test.

NO ENGINE IS ACQUIRED AT RUN TIME any more — not the GitHub release, not the container
image. Not because a pinned download is unusual here (the Containerfile downloads every tool
it bakes) but because those two decided the version, the network and the machine SILENTLY,
at test time, on whatever host ran the tests; and each quietly turned "the toolchain has no
promtool" into a green run, which is how the toolchain stayed without one. Missing promtool
is exit 3 (UNWIRED, never green); a PROMTOOL= that does not resolve is exit 2.

ONE WIRING: conformance/tests/l0-static/alert-rules-unit-tested, NOT a gate stage. The
`prom-rules` stage (ci/prom-rules.sh + its Makefile target + ci/gate.sh entry) is deleted:
it is the bespoke-per-check pattern b9f8807 had just removed from ci/l0.sh, and the
declarative replacement gives what a hand-written stage cannot — selection by
`conformance.home.k3s/scope: "whole-repo"` (asserted: the test is selected even under a
requirement filter matching nothing), requirement-attributed JUnit/coverage/ledger evidence,
and run_l1_offline.py's rule that a SKIP of a scope-declaring check is the runner's rc 3.
The scope declaration is load-bearing here: touched-requirements.sh keys apps/* to nothing
and platform/monitoring/* to R-OBS-01/02, never R-OBS-04, so a new untested PrometheusRule
would otherwise be gated by nothing.

The check asserts the pins and their lockstep, that the image bakes and records promtool,
that the promtool IN USE reports exactly the pin (a FAILURE, not a skip: the wrong engine
still prints SUCCESS), that exactly ONE harness exists and none fetches an engine, that
every rule-unit test file passes, and — on every run — that the harness CAN fail, by putting
a synthetic rule through it twice with one expectation mutated.

MISSING TESTS ARE A RATCHET, deliberately, and the reasoning is in the check's header. 51 of
58 alert rules have no unit test. Failing on all of them makes the gate red until ~51 tests
exist, so it gets disabled and protects nothing; merely reporting is exactly how the CNPG
tests came to be enforced by nothing. So the gap is DECLARED in the check as a shrink-only
register, printed with counts every run (13 alert files nothing tests at all; 35 named
alerts inside covered files that nothing asserts on), and it cannot grow: a new
PrometheusRule, or a new alert in an already-covered file, FAILS without a test, and a stale
entry FAILS too. A missing test is never an exit-3 skip — SKIPPED is reserved for the one
genuine environment gap, promtool being absent.

PROVEN, in the rebuilt image (promtool 3.14.0):
  * both suites pass through the single harness: cnpg 6 rules, monitoring 36 rules, SUCCESS.
  * the check passes: 95 assertions, 7/58 alert rules unit-tested, 13 declared gap files.
  * NOT VACUOUS, twice over. Shortening CNPGPrimariesCoLocated's `for: 30m` to 5m turns it
    red (pending expected at 25m/29m, got firing), reverted. Adding an untested
    PrometheusRule (platform/kubevirt/probe-alerts.yaml) turns it red on the ratchet,
    removed. The harness's own mutation self-test runs on every invocation.
  * the scope mechanism selects it: `run.sh --layer l0 --requirements r-nosuchreq-99
    --include-scope whole-repo --print-selection` lists alert-rules-unit-tested.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-13 00:02:27 -05:00
jakman85andClaude Opus 5 7057bbb711 fix(monitoring): alert when a Velero schedule has NEVER backed up, or is paused
VeleroNoRecentBackup could not fire for the failure mode that actually happened.
`(time() - velero_backup_last_successful_timestamp{schedule!=""}) > 24*3600` is the
right SHAPE — per-schedule, un-aggregated — but Velero only creates that series once
a backup for the schedule SUCCEEDS, and `time() - <absent series>` yields no series.
So it detects "backed up once, then stopped" and is structurally INERT on "never
backed up". Prod ran with `velero-daily` (the schedule carrying VOLUME DATA) paused
and never-successful: no volume backups at all, nothing alerted, and it was masked
because `velero-daily-resources-only` completed cleanly every 03:00, so every other
backup signal read green while only Kubernetes objects were protected.

A PromQL-only fix is impossible, verified rather than assumed: velero v1.18.1 exports
35 velero_* metric names and every one carrying a `schedule` label is created by a
backup ATTEMPT, not by the Schedule object. A throwaway `paused: true` Schedule on
prod produced ZERO velero_* series, and nothing exposes `spec.paused`. The fact is
not in the TSDB, so the Schedule CRs are exported via kube-state-metrics'
custom-resource-state collector — the path this repo already uses for
kube_node_labels — as kube_velero_schedule_{created,paused,protects_volume_data,info}.
Proven by running KSM v2.20.0 with this exact config against prod's API: the CRD
list/watch rule the chart adds is MANDATORY, not cosmetic — without it KSM emits the
CRS metrics as an empty set, silently.

Three rules, all keyed on PROPERTIES rather than schedule names:
  * VeleroScheduleNeverBackedUp (critical) — a Schedule older than 36h with no
    successful backup ever. The 36h grace comes from creationTimestamp so a newly
    added schedule is not paged before its first run is even due.
  * VeleroSchedulePaused (warning) — the direct root-cause signal; a paused backup
    schedule must never be silently indefinite.
  * VeleroNoVolumeDataBackup (critical) — THE ANTI-MASKING RULE. Fires unless some
    schedule with spec.template.defaultVolumesToFsBackup=true succeeded in 36h, so a
    healthy resources-only schedule can never make the platform look protected.
    Reading the property that DEFINES volume protection (not a name list) matches
    platform/velero/volume-policies.yaml and survives renames. `or vector(0)` is
    load-bearing: `count(<empty>) == 0` returns no series and would be inert —
    absence of the exporter is deliberately the alarm.

Adds the repo's first Prometheus rule-unit-test harness (platform/monitoring/tests/,
wired as the `prom-rules` gate stage). It flattens the COMMITTED PrometheusRule CRs —
never a copy — and pins every rule in the group both ways: quiet on today's healthy
prod state, firing on the reconstructed bad state, with `for:` durations asserted.
Two mutation checks confirm the tests are not vacuous: dropping `or vector(0)` and
breaking the `unless on (schedule)` join each turn the suite red. This is the tool
that makes both of this repo's recurring alert bugs — permanently-firing and
structurally inert — provable offline, which neither yamllint, Kyverno, nor a healthy
cluster can do.

Proof of the fix is by construction; the live metrics cannot show it any more, because
`velero-daily` was unpaused on 2026-09-12 and has since completed 2492/2492 items.
The throwaway probe Schedule and the probe KSM deployment were deleted and the
deletion confirmed; `velero-daily` remains unpaused.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-12 23:45:15 -05:00
jakman85andClaude Opus 5 6202d92c27 test(conformance): gate the URL desired state, and prove the selftest can fail
L0 (212 assertions, was 175):
  * runs ci/render-keycloak-client-urls.py --check, so client-urls.yaml must be exactly
    what the realm import renders. A hand edit that makes the two disagree is
    unmergeable -- this is what keeps the realm import the single source of truth for
    hostnames rather than just the place they were first typed.
  * asserts client-urls.yaml and the realm import are rendered by the SAME Flux
    Kustomization. postBuild.substituteFrom is per-Kustomization, so a split would let
    one ${BASE_DOMAIN} resolve to two different values and the realm would converge on
    a hostname the HTTPRoutes do not serve.
  * asserts the desired state uses no substitution token the realm definition lacks,
    names only clients the import declares, and declares no field outside the
    five-field write surface; that the CronJob mounts it readOnly at the path the
    script defaults to; and that the script, renderer and check agree on which fields
    are writable.
  * NEW mutations.py: injects 12 plausible regressions into the EXTRACTED script and
    requires --selftest to catch every one. A passing suite proves nothing if it cannot
    fail, and "reported success while the realm was broken" is precisely what this
    component exists to end -- so the same standard applies to its own test. ~20s.

L2: the audit Job now mounts keycloak-client-urls and asserts
KEYCLOAK_CLIENT_URLS_AUDIT_OK. Without that it would pass on a realm still holding
pre-migration redirect URIs -- the exact state prod was measured in.

Alerts: the existing Failing/Stale pair is EXTENDED to name redirect-URI drift, not
duplicated. One CronJob gets one pair; a second pair on the same job_name regex would
fire twice for one cause. No new critical, no new permanently-firing rule.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-12 21:26:12 -05:00
jakman85 efc6db6c1f feat(obs): alert on I/O pressure — the metric that missed the prod-1 outage
On 2026-09-07 06:05:21Z k3s-prod-1 went NotReady ("Kubelet stopped posting node
status") with the host up, pingable and SSH-able. The cause was disk I/O
starvation of the embedded etcd, from its own journal:

  slow fdatasync               took=3.56s / 6.71s / 4.95s / 3.40s (expects 1s)
  apply request took too long  took=8.30s                         (expects 100ms)
  etcdserver: too many requests

/proc/pressure/io FULL avg300 read 11.36 on k3s-prod-1 against 0.75 on
k3s-prod-2 (NVMe) and 1.29 on k3s-prod-3 — all three nodes put /data/k3s
(etcd's WAL) and /data/longhorn (every replica) on ONE partition, and node 1's
is a 2011 consumer SATA SSD with 61,440 reallocated sectors.

The stack alerted on CPU-PSI and memory and had NO I/O alert at all, so the
first signal the operator got was a node already out of the cluster. Adds:

  NodeIOPressureHigh      full IO PSI > 5%  for 10m  warning
  NodeIOPressureCritical  full IO PSI > 10% for 5m   critical

Thresholds are measured, not guessed: rate() is a 0-1 fraction, so the outage's
11.36% is 0.1136 and the healthy steady state on the same node is ~0.01.
Verified live that node-exporter already exports
node_pressure_io_{stalled,waiting}_seconds_total for all three prod nodes, so
these rules fire on arrival — no new exporter, no scrape change. (etcd's own
fsync histograms are NOT available: kube-prometheus-stack's kubeEtcd scrape job
is deliberately disabled for k3s, so PSI is the signal we actually have.)

PSI *full* (every runnable task blocked on disk), not *some*: `some` is noisy on
a storage node and did not separate the failing node from its peers.

Dashboard gains the matching I/O row and is retitled accordingly. Not scoped to
prod — dev shares this file and its k3s VMs are HDD-backed, where the same alert
is if anything more likely to earn its keep.

Co-Authored-By: Claude Opus 5 <[email protected]>
(cherry picked from commit cb28fc80e7e2085d2539530d55f90fc92e3b1bba)
2026-09-07 02:46:26 -05:00
jakman85andClaude Opus 5 6a8953e288 feat(prod): observability for the two failure modes that went unseen, plus OIDC self-healing
Minimal prod delivery, authored directly on main (= prod's live revision d1a6628)
rather than by merging work/prod-standup-campaign. That branch carries the DNS apex
inversion, which would have set prod's BASE_DOMAIN to home.keithjackson.dev; prod
runs external-dns with policy: sync and txtOwnerId: prod, so it would have begun
rewriting apex records dev owns while the non-k3s prod still serves 443 there.
Operator sequencing is "dev migrates first". Nothing under clusters/ is touched
here at all, which is what makes this safe to land now.

Also deliberately EXCLUDED, because prod's live cluster-vars has no CNPG_BACKUP_PATH
key and StrictPostBuildSubstitutions would fail the whole tier: the R2 rework of
platform/velero/ and the CNPG destinationPath changes. Those land as
feat/r2-backup-prod together with the endpoint and bucket knobs.

WHAT THIS FIXES

1. Nothing was watching CNPG. All three prod databases have run since bootstrap with
   ContinuousArchiving=False and firstRecoverabilityPoint=null, and no alert existed
   anywhere. Because archive_mode=on and the archive command fails, Postgres refuses
   to recycle WAL: keycloak-db holds every segment ever written (257 MiB on a 5 GiB
   volume, ~6.8 MiB/h) — roughly 29 days to a disk-full PANIC on the cluster's SSO
   database. Found by hand, 38h late. CNPGWALArchiveBacklog would have fired within
   the hour, and evaluates to 3 firing series on prod today.
   Rules key on cnpg_collector_* rather than cnpg_pg_stat_archiver_*, because
   nextcloud-db's exporter cannot log in to its own database (permission denied for
   database "nextcloud", both clusters) so the pg_stat_archiver family does not exist
   for it — the obvious metric would have been blind to one database in three.

2. No PVC outside namespace=monitoring had any fill alert. New rules are partitioned
   by namespace so they cannot double-fire with MonitoringVolumeFillingUp, pinned to
   job="kubelet" (the apiserver copy of the same series reports namespace=default),
   and guarded by inodes > 0 — block-mode PVCs such as unifi-rootdisk report
   available=0 forever and would otherwise have fired critical permanently.

3. VPNTunnelDown could never clear on a cluster with no gateway node; it has been
   firing critical on prod since 2026-09-05. Now guarded so prod self-arms the moment
   a node carries the egress-gateway label, with dev's behaviour unchanged today.

4. The Keycloak realm import fails OPEN: an unresolved placeholder is stored
   LITERALLY and the import still reports success, then sits at Done=True and never
   re-runs. On 2026-09-06 all 12 prod OIDC clients held the literal
   $(env:..._CLIENT_SECRET) string and every SSO login failed, while every signal was
   green. The CronJob is the level-triggered correction; two alerts make its silence
   observable. Repaired live already — this stops it recurring.

Also: the R-NET-04 conformance scan descended into nested agent worktrees under
.claude/, counting 4 egress policies where 1 is authored.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-07 00:59:22 -05:00
jakman85andClaude Opus 5 c8c1d2935d feat(dns): per-environment BASE_DOMAIN — prod moves to its own subdomain
gate / gate (push) Has been cancelled
gate / conformance (push) Has been cancelled
INCIDENT FIX. Prod's external-dns DELETED EVERY ONE OF DEV'S PUBLIC DNS RECORDS. Both
clusters ran policy: sync against the SAME Cloudflare zone with the SAME implicit
txtOwnerId (`default`), so prod believed it owned dev's records, found no matching sources,
and removed them plus their TXT registry entries. Dev recovered ~30s after prod was scaled
to 0; verified restored against Cloudflare directly (my first check went through a pfSense
override and falsely showed healthy — local resolvers are not evidence about public DNS).

THE MISS WAS MINE, and it was a failure of imagination in how I briefed every agent. I put
"never touch dev" in brief after brief and enforced it — separate kubeconfigs, verified
--limit, sha-checked dev's kubeconfig before and after. Every one of those guards held. NONE
of them covered SHARED EXTERNAL RESOURCES. Prod reconciling its OWN correctly-authored
manifests reached across a third party and destroyed dev's state. Cluster-to-cluster
isolation was verified; the dependency that mattered was cluster-to-Cloudflare.

Operator's architecture: dev -> *.dev.home.keithjackson.dev, prod ->
*.prod.home.keithjackson.dev, apex CNAME <svc>.home -> <svc>.prod.home.

PHASE 1 ONLY (this commit): prod moves to its own subdomain. DEV IS NOT MIGRATED and its
effective hostname stays home.keithjackson.dev, so dev renders byte-identically and nothing
live moves. That alone ends the collision and unblocks prod. Phase 2 (dev -> dev.home. +
apex CNAMEs) is deferred to when the operator is present: it relocates Keycloak's issuer and
12 clients' redirect URIs, forces a rolling k3s restart and kubectl SSO re-issue for every
user, and moves gitea.home. — which is BOTH the GitOps source and the current push target.

BASE_DOMAIN WAS A DEAD KNOB — it existed in cluster-vars but the status report flagged it as
referenced by nothing, because hostnames were hardcoded throughout. Now real: 141 refs.
Searched the AUTHORITATIVE reconciled set by resolving each Flux spec.path transitively via
conformance/lib/status.py — the same resolver the L0 gate uses, so "what Flux reconciles"
has one definition. 185 occurrences across 47 files in 154 reconciled files. Tokenized:
Gateway listeners, the wildcard Certificate, coredns-custom, external-dns, Keycloak
instance/realm (26 redirect URIs), oauth2-proxy, Grafana OIDC, all HTTPRoutes, Homepage's 15
links, 30 runbook_urls, unifi cloud-init, render.py's ZONE constant (which drove
--oidc-issuer-url/--cookie-domain/--whitelist-domain on every forward-auth sidecar) and 11
catalog/ ServiceDefinitions re-rendered canonically. Left alone: 43 comment/prose
occurrences and non-reconciled paths.

TWO THAT CANNOT BE TOKENIZED, flagged not forced:
  - headlamp's OIDC URLs live inside a SOPS-encrypted Secret; re-encrypting rewrites the MAC
    over every value and the OFFLINE harness cannot verify it (kustomize does not decrypt),
    so an error would break live-dev SSO with no pre-flight proof. Prod needs its own copy
    anyway — client secrets are realm-scoped.
  - kube-apiserver --oidc-issuer-url is a k3s SERVER FLAG, not a manifest, so Flux can never
    reach it. Done on the inventory seam instead (k3s_base_domain -> k3s_oidc_issuer_url,
    overridden in group_vars/k3s_prod). Verified per host: dev keeps the default, prod gets
    prod.home.

EXTERNAL-DNS OWNER, the actual incident cause: txtOwnerId is now explicit per environment —
dev renders exactly `default` (the chart default it was already using, so its existing
records stay recognised) and prod gets `prod`. The BASE default is a NON-COLLIDING SENTINEL,
deliberately not `default`, so a future environment that forgets the knob owns nothing and
can delete nothing rather than silently inheriting dev's identity.

I OVERRODE ONE AGENT DECISION against our own prior finding: it narrowed prod's
domainFilters to prod.home.keithjackson.dev as defence in depth. FINDING F-DNS1
(DECISIONS-LOG 2026-08-17) already proved a subdomain filter DROPS THE PARENT ZONE —
ExternalDNS generates the record then skips it with "no hosted zone matching record DNS
Name". Prod would have published NOTHING. Set to the ZONE (keithjackson.dev) like dev.
Isolation comes from the subdomain split plus txtOwnerId, which is what the incident
actually needed and what a domain filter cannot provide.

DEV PROVEN UNCHANGED: 11 of 12 substituting paths byte-identical; the 12th differs by
exactly one line, `+ txtOwnerId: default` — the value dev was already using implicitly.
POSITIVE CONTROLS confirm the harness is not blind: perturbing BASE_DOMAIN moves 10 of 12
hashes (the 2 that don't provably contain no hostname), perturbing the owner id moves
exactly 1. Prod's rendered output has ZERO home.keithjackson.dev references outside prod.,
and its cert renders *.prod.home.keithjackson.dev — no overlap with dev's.

L0 substitution assertions 106 -> 254; BASE_DOMAIN is no longer flagged dead. Gate PASS.

PROD REMAINS SUSPENDED (platform + 10 downstream tiers) pending review; nothing applied.

Serves: R-ENV-02, R-DNS-01, R-DNS-02, R-DNS-03, R-TLS-01.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-04 22:43:54 -05:00
jakman85andClaude Opus 4.8 a720c73fcd monitoring: node CPU-pressure alerts + PSI/load dashboard (#4)
Adds NodeCPUPressureHigh (CPU PSI 'some' > 15% for 15m) and NodeCPULoadHigh (load5/core > 1 for 15m)
to platform-health.nodes, plus a 'Nodes — CPU / Memory Pressure' Grafana dashboard (PSI + load-per-core
+ utilization). These surface the bursty CPU contention that averaged CPU%/kubectl top hides — the
signal behind 'spikes cause blips of delay'. Makes the 6->8 vCPU resize measurable.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 21:51:15 -05:00
jakman85andClaude Opus 4.8 3e61f817b6 kps: raise Prometheus (2->3Gi) + Grafana (512->768Mi) memory limits
Both were pinned at ~98% of their limits (Prometheus 2002/2048Mi, Grafana 499/512Mi) with no
headroom for TSDB compaction / dashboard-render spikes — the classic OOM setups. Nodes are 24Gi at
38-44% used (~14Gi free each; the '~22 GiB ceiling' comment predates the 16->24Gi node bump), so the
extra headroom is comfortable. Grafana request 256->384Mi, Prometheus request unchanged.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 21:33:40 -05:00
jakman85andClaude Opus 4.8 954b9616b9 loki: chart 6.x -> 7.x (Loki 3.6.x; stay-current)
chart 7 major bump. Verified chart 7.3.0 renders identically for this SingleBinary/filesystem/
Longhorn config (one loki StatefulSet, no extra read/write/backend/cache pods, no schema errors).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 16:21:32 -05:00
jakman85andClaude Opus 4.8 cbc2301b30 docs: reconcile docs/comments with post-upgrade cluster state
Text-only cleanup after the upgrade campaign. Updates stale version
strings, prose, and comments to the verified current facts; no
Kubernetes behavior or version pins changed except the kubectl
toolchain bump (below).

Verified facts applied: k3s v1.36.4+k3s1, Debian 13 trixie,
Cilium 1.20.1 / Gateway API v1.6.1, Longhorn 1.12.1, node RAM 24 GiB,
dedicated virtio2 SSD etcd disk per node, Velero chart 12.x / v1.18,
Grafana 13.2.0.

- Version strings across infra/ and platform/ READMEs + comments
- kubectl toolchain 1.31.4 -> 1.36.4 (devcontainer/ci/conformance
  versions.env; 1.31 vs a 1.36 cluster exceeded the +-1 skew)
- Retired-single-apps-Kustomization refs -> apps-wave-0/1/2 + apps-vms
  with per-wave SOPS decryption (flux/clusters docs + bootstrap.sh)
- COMPLETED/historical banners on the three executed plan docs
- Resolved TODO(WS-SEC) markers -> Renovate-maintained ranges
- Appended dated DECISIONS-LOG entry (2026-08-30) superseding the
  2026-08-26 LIVE STATE line

Left as revalidation items (not blind-edited): external-snapshotter
v8.2.0 vs 1.36, Cilium ext_authz/forward-auth relevance under 1.20.1,
conformance ImageVolume feature-gate assertions under 1.36.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 15:13:12 -05:00
jakman85andClaude Opus 4.8 b2b1aa55e2 kps: bump Grafana memory limit 256Mi->512Mi (Grafana 12.x OOMKill was root cause of 65->88 upgrade timeout)
Grafana 12.x bundled in kps 88 OOMKilled (exit 137) at 256Mi during grafana-apiserver/unified-storage
startup — no fatal log, just SIGKILL. The new Grafana pod never became Ready, so Helm --wait ran the full
20m and rolled back to 65.8.1 every time. 512Mi holds.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 14:52:06 -05:00
jakman85andClaude Opus 4.8 00d895d25f kps: 20m timeout + no-rollback remediation for the 65->88 catch-up
The 65->88 multi-major upgrade exceeded the default 5m Helm timeout (full operator/KSM/
node-exporter + Prometheus/Alertmanager StatefulSet rollout), so Flux rolled back to 65.8.1
four times and Stalled, blocking the platform kustomization and everything downstream.
CRDs pre-applied server-side at operator v0.93.1.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 12:08:29 -05:00
jakman85andClaude Opus 4.8 037aa7fe9a Component catch-up: kube-prometheus-stack 65->88 (po v0.93, k8s 1.36); CRDs pre-applied
Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 11:23:13 -05:00
jakman85andClaude Opus 4.8 19a368b237 Component catch-up batch 1: external-dns 1.21, oauth2-proxy 10.x, Alloy 1.x, CNPG in-place flag
Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 11:21:55 -05:00
jakman85andClaude Opus 4.8 eb31d2ef58 fix(monitoring): cap Prometheus TSDB by size to stop false absent()/==0 alerts
The 7 falsely-firing platform alerts (KeycloakDown, KeycloakDatabaseDown,
KubeAPIDown, KubeletDown, VPNTunnelDown, KubeVirtControlPlaneDown,
CDINoDefaultStorageClass) share ONE root cause, not per-rule label mismatches:
the Prometheus PVC is 100% full ("no space left on device" on every WAL commit).

Evidence from the live dev cluster:
- /prometheus is 4.8G/5Gi, 0 bytes free; every scrape logs "Scrape commit
  failed ... write to WAL: no space left on device". Scrapes still return 200
  (targets show healthy, lastScrape=now) but samples are never stored, so the
  TSDB head froze at 2026-08-28 13:45 UTC while the pod clock reads ~19:33 UTC.
- Instant queries at "now" therefore return an EMPTY vector, so every
  absent()/==0 platform rule trips. Evaluated at the last-good-sample time each
  expr is correctly FALSE (keycloak-0/keycloak-db-1 ready=1, apiserver+kubelet
  up=1 x3, tun0 series present, kubevirt control-plane expr empty, CDI default
  present) — the rules are correct; the monitor was simply blind.

`retention` alone prunes only by AGE: this cluster is 3d2h old with 3d dev
retention, so time-pruning has NEVER run and 3d of block churn (~1.2Gi/day) plus
a WAL that ballooned past 1Gi overran the 5Gi disk. Fix adds a size-based
retention cap (new MONITORING_PROMETHEUS_RETENTION_SIZE knob) kept below each
env's PVC so Prometheus drops oldest blocks before the disk fills, and bumps the
dev PVC 5Gi->8Gi for real WAL/head/compaction headroom.

- platform/monitoring/kube-prometheus-stack.yaml: retentionSize: ${knob}
- clusters/base/cluster-vars.yaml: knob default 8GiB (base 10Gi PVC)
- clusters/dev/kustomization.yaml: PVC 5Gi->8Gi, retentionSize 5GiB
- clusters/prod/kustomization.yaml: retentionSize 45GiB (50Gi PVC)
- platform/monitoring/README.md: knob table + rationale

Deploy note (PM): the PVC is already 100% full, so Prometheus cannot self-prune
until it can write. The 5Gi->8Gi bump must land as a Longhorn online expansion
(operator PVC expansion / manual patch); once free space returns, retentionSize
keeps it healthy. Watchdog left untouched.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-28 14:38:12 -05:00
jakman85 bc0982c213 fix(grafana): roll Grafana to load the OIDC client-secret (R-IDP-01)
Grafana's pod predated the grafana-oidc-credentials secret, so generic_oauth started with
an empty client_secret (disabled) → /login/generic_oauth didn't redirect to Keycloak.
Add a podAnnotation to force one roll; bump on future OIDC secret changes.
2026-08-24 22:57:00 -05:00
jakman85 01bcb99337 Merge feature/phase4-image-automation: Phase 4 hands-off updates (R-UPD-01/02/03) 2026-08-24 22:17:44 -05:00
jakman85andClaude Opus 4.8 bfec9d869e feat(updates): alert on failed / rolled-back updates (R-UPD-02 + R-OBS)
Add platform-health.automated-updates PrometheusRule group carried by platform-config:
ImageUpdateAutomationFailing (write-back broken -> advances silently stop),
ImagePolicyStalled (registry/range can't resolve a stable tag), and UpdateHealthGateFailed
(a bad update health-gated and auto-rolling-back via HelmRelease remediation). Routes to
Alertmanager email so a bad update is visible.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-24 22:14:54 -05:00
jakman85andClaude Opus 4.8 ed6a772599 feat(keycloak): provision SSO client secrets + re-enable oauth2-proxy (R-IDP-01/02/04)
Generate the 3 OIDC client secrets (SOPS-encrypted, minimal manifests) so the realm
import can inject the grafana + oauth2-proxy client secrets and both consumers match:
- platform/keycloak/keycloak-realm-clients.sops.yaml (grafana + oauth2-proxy client secrets)
- platform/oauth2-proxy/oauth2-proxy-credentials.sops.yaml (client-id/secret/cookie)
- platform/monitoring/grafana-oidc-credentials.sops.yaml (grafana client secret)
Wire each into its component kustomization and re-enable oauth2-proxy in platform +
platform-config (reverses the temp deferral now that its secret exists).

Values generated by PM per operator instruction (random; recorded out-of-repo at
~/.config/home-k3s/keycloak-sso-secrets.txt for later rotation). Encrypted via sops in the
dev container to the age recipient in .sops.yaml; plaintext never committed.

Serves: R-IDP-01, R-IDP-02, R-IDP-04, R-SEC-01.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-24 22:08:04 -05:00
jakman85 4bebd4b6d2 keycloak: coverage tests + dashboard + reword cross-cutting tags 2026-08-24 21:07:27 -05:00
jakman85 ce83c6af3b WIP keycloak stack (gate probe) 2026-08-24 19:52:25 -05:00
jakman85andClaude Opus 4.8 d519ede4e3 monitoring: retarget VPNTunnelDown to node tun0 presence; drop obsolete EgressGatewayUnhealthy
gluetun retirement removes the gluetun_vpn_up gauge and the in-cluster gateway pod. Point
VPNTunnelDown at absent(node_network_receive_bytes_total{device=tun0}) — tun0 exists iff the
host OpenVPN tunnel is up (node_network_up unreliable: tun0 operstate=unknown). This also
fires if the gateway node/node-exporter is down (series goes stale). Remove the pod-readiness
EgressGatewayUnhealthy alert — there is no gateway pod under ADR-0015.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-24 14:41:20 -05:00
jakman85andClaude Opus 4.8 7b619f8bb0 fix(monitoring): Prometheus memory limit 1Gi -> 2Gi (OOMKilled on compaction)
prometheus-...-0 was OOMKilled (exit 137) every ~4min during TSDB compaction/checkpoint
(261 restarts/37h). Raise limit to 2Gi + request to 512Mi; nodes have headroom.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-24 00:04:17 -05:00
jakman85andClaude Opus 4.8 eeb97208fa fix(monitoring): move PrometheusRule alerts to platform-config (CRD ordering)
Enabling monitoring deadlocked the platform Kustomization: alerts.yaml ships
PrometheusRule CRs whose monitoring.coreos.com CRDs are installed by the
kube-prometheus-stack HelmRelease in the SAME pass → 'no matches for kind
PrometheusRule' → atomic apply failure → NO monitoring HelmReleases created.
Same controllers/configs fix as cert-manager/kyverno: drop alerts.yaml from
platform/monitoring and apply it via platform-config (dependsOn platform), so the
monitoring CRDs exist first. Verified: platform has 0 PrometheusRule (keeps the 3
monitoring HRs); platform-config has the 8 alert rules; gate PASS.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-21 22:30:01 -05:00
jakman85andClaude Opus 4.8 dfde5292d7 feat(phase4): deploy monitoring (kube-prometheus-stack + Loki + Alloy + Alertmanager)
Enable monitoring in platform/kustomization.yaml (Phase 4). Grafana admin +
Alertmanager SMTP secrets are provisioned (SOPS) and wired; Longhorn SC is up for
Prometheus/Loki PVCs. Set the Alertmanager receiver 'to:' to a valid inbox
([email protected]) so the config loads (REPLACE-ME is not a valid address);
operator can change it. NOTE: smtp_from ([email protected]) differs from
the Gmail auth user — Gmail may reject/rewrite unless a send-as alias is configured;
that only affects email delivery at alert time, not stack health.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-21 22:06:23 -05:00
jakman85andClaude Opus 4.8 a108d5ab98 correction: credential-forward + unified graph; activate SOPS (author-first)
Operator directive: don't diverge architecture to avoid asking for credentials;
provision them upfront via SOPS and keep the existing (unified) graph.

Roadmap reconciliation: Phase 2 = Network/Storage/TLS/DNS/Ingress, so
cert-manager/externaldns/gateway (the credential-gated pieces) ARE Phase 2;
monitoring is Phase 4. Earlier A2/rollout scope was inverted by credential-avoidance.

Reverts (credential-driven): remove clusters/dev/rollout/ + the $patch:delete's;
restore unified base graph (dev = ../base + cluster-vars + SOPS decryption,
R-ENV-02 intact); restore monitoring files (Phase 4). Kept non-credential
improvements: tofu for_each/rejoin, Kyverno parametrization + webhook excludes.

platform/kustomization.yaml now phased (single shared list): Phase-2 set =
kyverno, cilium, longhorn, cert-manager, externaldns, gateway; later components
commented with phase markers.

SOPS activated: .sops.yaml at repo root; bootstrap/sops/secret-templates/*.yaml.example
for all secrets (cloudflare x2, grafana, alertmanager-smtp, keycloak, oauth2-proxy, pia);
bootstrap/sops/CREDENTIALS.md checklist; pre-wired commented cloudflare-api-token lines
in cert-manager + externaldns; filled non-secret ACME email. Agents never touch real
secret values (operator encrypts).

Validated: kubectl kustomize dev(unified)/prod/platform(Phase-2 only), templates inert,
make -C ci gate PASS.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 22:09:20 -05:00
jakman85andClaude Opus 4.8 d9a80e5350 phase2-prep: per-component no-secret rollout + component hardening (author-first)
Prep only — nothing deployed; running cluster untouched.

Reconciliation graph (operator-approved Option A): author clusters/dev/rollout/
= 4 per-component Flux Kustomizations (kyverno->cilium->longhorn->monitoring,
monitoring dependsOn longhorn). Dev overlay $patch:delete's the monolithic base
platform/apps and adds ./rollout, so only the no-secret tier reconciles; the
secret-blocked components are simply not created until hand-offs arrive. The
no-secret tier carries no SOPS content, so it needs no sops-age key. prod is
untouched (still builds the monolith). Convergence path coded in (delete rollout/
+ the two deletes) — R-ENV-02 divergence flagged for architect review.

Component hardening via cluster-vars (prod keeps strict posture):
- KYVERNO_VALIDATION_ACTION Enforce->Audit(dev), _WEBHOOK_FAILURE_POLICY
  Fail->Ignore(dev), _ADMISSION_REPLICAS 3->1(dev); webhook namespaceSelector
  excludes system+platform namespaces.
- MONITORING_STORAGE_CLASS var; GRAFANA_ADMIN_SECRET var (dev ''=chart default);
  Alertmanager SMTP/secret deferred to Phase-4 with verbatim re-enable markers.

Cilium parity verified against the live CNI (no-op adopt). Validated:
kubectl kustomize dev/prod/all-components, envsubst->YAML parse, make -C ci gate PASS.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 21:34:57 -05:00
jakman85andClaude Opus 4.8 cc89b4b830 Autonomous session: Phase-2 platform authoring + Flux bootstrap progress
Author-only Phase-2 components (platform suspended; cluster untouched):
- platform/longhorn: 3-replica SC + bulk external-mount indirection (R-STATE)
- platform/monitoring: kube-prometheus-stack + Loki + Alloy (dev-trimmed) + 8 alert rules (R-OBS)
- platform/cilium: parity fix (k8sServiceHost=10.73.0.11 + masquerade) safe to adopt Phase 2
- conformance: partial L2 tests (worker hit session limit; incomplete — see DECISIONS-LOG K2)
- bootstrap/gitea: fix rootless-podman perms (host bind-mount -> named volume)

Flux installed on the cluster; host Gitea up + repo pushed; GitRepository BLOCKED by
host firewalld (VM->10.73.0.1:3000) — needs one operator sudo command (DECISIONS-LOG).
Known issue K1: cluster-vars substitution-var case mismatch (fix before un-suspend).

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 14:32:47 -05:00
jakman85andClaude Opus 4.8 af4f6c07ae T-0.1 Flux GitOps layout + dev/prod overlays + platform component skeletons (R-GITOPS-01/03, R-ENV-02, R-PLAT-01)
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 00:08:31 -05:00