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jakman85andClaude Opus 5 a2440a3125
gate / gate (pull_request) Successful in 1m57s
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feat(upgrades): automated OS reboots (kured) + security-only unattended-upgrades, and give Renovate a runner
Two halves of one repeatable upgrade process. Neither works alone.

(a) OS upgrades and reboots

platform/kured/ — Kubernetes Reboot Daemon, chart 6.1.0/app 1.23.0, in its own
Flux Kustomization (dependsOn platform, wait:true). NOT in platform/kustomization.yaml:
that tier gates platform-config and every apps wave, so a wedged reboot daemon there
could stall every application. A component added to make maintenance safer must not be
able to cause an outage.

infra/ansible/roles/unattended_upgrades/ — new role (node_baseline is touched by other
open branches, and this is a different lifecycle), enabled for prod in group_vars.

The human gate is the SENTINEL, which is how this honours node_baseline's "IT DOES NOT
REBOOT" (k3s-prod-2 hung on a warm reboot 2026-09-03) and cluster-upgrade-plan.md's
rejection of automating away the gate between nodes: u-u is security-only with the
kernel blacklisted, so it essentially never writes /var/run/reboot-required. That file
appears when an operator deliberately runs node-baseline.yml --tags kernel. kured then
does only the mechanical half, including the ordering rule node_baseline has to shout.

Quorum: concurrent reboots are structurally impossible, not merely unlikely.
concurrency:1 plus kured's single lock annotation (API-server optimistic concurrency),
and lockTtl:0 — an expiring lock is exactly the 3-node etcd catastrophe, so a hung node
holds it forever and nothing cascades.

Longhorn: measured 25 volumes x 3 replicas, hard anti-affinity, 600s replenishment wait,
serialized rebuild — so every drain degrades ALL volumes to 2/3 and the inter-node gate
must be volume robustness, not pod readiness. Doubled: lockReleaseDelay 30m
(unconditional) plus kured's Prometheus alert gate (semantic).

alertFilterMatchOnly:true is load-bearing — the flag inverts the regexp's meaning, and
under the chart default kured would have been blocked on day one by the five alerts
measured firing with no end in sight, and never rebooted anything.

Kernel floor (kernel >= 6.13, EFI memattr): excluded TWICE. The running kernel comes
from o=Debian Backports, which is not an allowed origin, so u-u cannot see a kernel
upgrade; and ^linux- is blacklisted anyway so widening origins later cannot re-arm it.
Asserted against apt-config dump, not against the file just written. 6.12 kernels are
still installed and bootable on all three nodes, and nothing was held.

Closes a silent no-op: update-notifier-common was absent on all three nodes, so NOTHING
could create the sentinel. kured alone would have idled forever at 1/1 Running.

platform/kured/alerts.yaml — three rules over kured's only metric, with a companion
promtool suite pinning each both ways, plus runbooks/node-reboot-automation.md.
Window is DAILY 03:00-06:00 because a weekly one forces for:8d, longer than this
cluster's 7d Prometheus retention.

(b) Image/dependency automation

Renovate was aspirational: renovate.json present and complete, with no workflow, no
in-cluster workload, and its docker+kubernetes managers disabled — so every plain
image: tag was maintained by nothing while seven files claimed otherwise.

.gitea/workflows/renovate.yaml — scheduled daily, dry_run default true for a safe
first run, and a preflight that FAILS (not skips) without RENOVATE_TOKEN, because a
skipped Gitea job reports success and that is how this stayed inert.

Renovate now owns both halves; Flux image-automation is formally closed: it pushes
commits rather than opening PRs (bypassing CLAUDE.md §1), and it cannot work here
anyway — main is protected user_can_push:false and the flux-system GitRepository has
no secretRef. Its controllers are installed and have idled 43 days with zero CRs.

conformance/: +34/-0, one new SCRAPE_OWNERS entry claiming kured_. Weakens nothing;
tightens the check for this component (requires service.create+metrics.create, both
chart-default false, plus a companion NetworkPolicy requirement). Required because
assertion (3) fails an alert over an unclaimed metric and KNOWN_UNWIRED_METRICS is
shrink-only.

Sensitive paths touched: clusters/**, conformance/**, .gitea/** — needs a non-author
approving review; /approve-override deliberately NOT posted.

NOT verified: no OS upgrade run, no node rebooted, no lock observed, the Ansible role
never executed, and whether CNPG switches its primary on a drain-induced eviction (the
most likely way the first real reboot fails). Full list in the handoff entry.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-10-18 00:10:29 -05:00

125 lines
8.5 KiB
YAML

---
# Alert rules for the kured reboot automation.
#
# WHY THESE THREE, AND WHY THEY ARE NOT OPTIONAL. Reboot automation's characteristic failure is
# SILENCE, not noise. Every way this component can break leaves a cluster that looks perfectly
# healthy: a sentinel nothing writes, a Service the chart did not create, a NetworkPolicy that drops
# the scrape, a taint that excludes a node, a drain wedged on a PodDisruptionBudget, a cluster lock
# held forever by a node that hung on warm reboot. In none of those cases does anything turn red on
# its own. kured itself stays 1/1 Running throughout.
#
# kured EXPOSES EXACTLY ONE METRIC. Read from cmd/kured/main.go:92-96 and :113 on 2026-10-17 — the
# only `prometheus.MustRegister` in the tree is a GaugeVec `Subsystem: "kured"`, `Name:
# "reboot_required"`, labelled `{node}`. So the full vocabulary available is
# `kured_reboot_required{node="..."}`, 1 when the sentinel exists and 0 when it does not. Each rule
# below is built from that one series plus `kube_node_info` (kube-state-metrics), and nothing else.
# There is deliberately no rule over an invented metric name: this repo has shipped a
# structurally-inert alert before (VeleroNoRecentBackup over an absent series, which is why
# platform/monitoring/tests/run.sh exists), and an alert that cannot fire is worse than no alert
# because it also removes the suspicion that would have caught it.
#
# THESE RULES LIVE HERE, NOT IN platform/monitoring/alerts.yaml, for two reasons. (1) The unit-test
# harness treats a `<manifest>.promtool-test.yaml` COMPANION as covering just its sibling, whereas a
# `tests/*.test.yaml` SUITE covers every PrometheusRule in its directory — so shipping them beside
# the component keeps the test obligation local and legible (the platform/cnpg precedent). (2)
# platform/monitoring/alerts.yaml is concurrently edited by other open branches; adding 3 rules to
# its tail would create a merge conflict for no benefit.
apiVersion: monitoring.coreos.com/v1
kind: PrometheusRule
metadata:
name: kured
namespace: kured
labels:
app.kubernetes.io/name: kured
spec:
groups:
- name: platform-health.node-reboots
rules:
# ── 1. IS THE MECHANISM ALIVE AT ALL? ────────────────────────────────────────────────
- alert: KuredNotReporting
# `absent()` yields a series only when the ENTIRE vector is empty, so this fires when no
# node at all is publishing — kured gone, or its Service/ServiceMonitor/NetworkPolicy
# regressed so nothing is scraped. It stays quiet while a single node is mid-reboot
# (the other two still report), which is what makes it specific to a wiring failure
# rather than to a reboot in progress.
#
# THIS IS THE RULE THAT GUARDS THE OTHER TWO. Both of them read `kured_reboot_required`,
# so if that series stops existing they go quiet and look like good news. This one turns
# the absence itself into the signal. The specific regression it is aimed at: the kured
# chart defaults `service.create` and `metrics.create` to FALSE, and Longhorn has already
# demonstrated on this cluster (see the companion note in
# conformance/tests/l0-static/alert-metrics-have-scrape-targets/check.sh) that a
# NetworkPolicy can let targets be DISCOVERED while every scrape times out and the TSDB
# stays empty.
expr: absent(kured_reboot_required)
# 30m absorbs a HelmRelease upgrade rolling the DaemonSet and a Prometheus restart,
# without tolerating a real wiring break for more than one quiet night's worth of time.
for: 30m
labels:
severity: warning
annotations:
summary: kured is publishing no reboot_required series on any node
description: >-
No node is reporting kured_reboot_required, so the reboot automation is either not
running or not being scraped. While this is true, OS reboots are not happening and
the two alerts that would say so (KuredRebootPending, KuredNodeCoverageGap) are
themselves inert. Nodes will silently accumulate pending kernel upgrades.
runbook_url: "https://${BASE_DOMAIN}/runbooks/node-reboot-automation"
# ── 2. IS IT ALIVE ON *EVERY* NODE? ──────────────────────────────────────────────────
- alert: KuredNodeCoverageGap
# A per-node agent that silently covers only some nodes is the subtler half of the
# liveness question, and `absent()` cannot see it. kured publishes one series per node it
# runs on; kube-state-metrics publishes one `kube_node_info` per node that exists
# (measured 2026-10-17: 3, matching the 3 nodes). A shortfall means at least one node has
# no reboot automation — most likely a new or re-provisioned node carrying a taint this
# DaemonSet does not tolerate (it declares none, because no prod node is tainted today).
# That node would then never reboot, with nothing else to indicate it.
expr: count(kured_reboot_required) < count(kube_node_info)
# 2h, chosen to sit comfortably ABOVE the duration of a healthy reboot. A node being
# rebooted stops publishing for a few minutes and legitimately creates a shortfall; a
# node that is still missing after two hours is either genuinely uncovered or has hung on
# reboot, and both of those want a human.
for: 2h
labels:
severity: warning
annotations:
summary: kured is not running on every node
description: >-
Fewer nodes are reporting kured_reboot_required than exist in the cluster, so at
least one node has no reboot automation and will never be rebooted by it. Most
likely a node carries a taint this DaemonSet does not tolerate, or has hung during
a reboot.
runbook_url: "https://${BASE_DOMAIN}/runbooks/node-reboot-automation"
# ── 3. IS A REBOOT STUCK? ────────────────────────────────────────────────────────────
- alert: KuredRebootPending
# A node has wanted a reboot for longer than a full maintenance window plus margin, so
# the reboot was OFFERED and did not happen. The causes are all real and all invisible
# otherwise: the Prometheus alert gate is blocking on a degraded Longhorn volume that is
# not recovering; the drain hit `drainTimeout` against a 0-disruption PDB; another node
# holds the cluster lock and never released it (`lockTtl: 0` means a lock held by a hung
# node is held FOREVER — that is deliberate, see helmrelease.yaml, and this is the alert
# that makes the resulting stall visible).
expr: max by (node) (kured_reboot_required) == 1
# 36h, and the window being DAILY is what makes this number meaningful — see the window
# block in helmrelease.yaml. With a 03:00-06:00 window every day, a pending reboot waits
# at most ~24h legitimately, so 36h means at least one full window elapsed without the
# reboot completing. On a weekly window this threshold would have to exceed 7 days, which
# is longer than this cluster's 7d Prometheus retention and is reset by any Prometheus
# restart past the 1h for-outage-tolerance — i.e. unreliable in the one direction that
# matters. Note this alert can still be LATE for that reason, but it cannot be spurious.
for: 36h
labels:
severity: warning
annotations:
summary: Node {{ $labels.node }} has needed a reboot for over 36h
description: >-
kured reports a pending reboot on {{ $labels.node }} that has survived at least one
full 03:00-06:00 maintenance window. The reboot is being blocked, not merely
waiting: likely a degraded Longhorn volume holding the Prometheus alert gate, a
drain timing out against a PodDisruptionBudget, or a stale cluster lock held by a
node that did not come back. The kernel or security update that needed the reboot is
installed but NOT running.
runbook_url: "https://${BASE_DOMAIN}/runbooks/node-reboot-automation"