recovery: keep flux held before safe resume

configs/ananke.tethys.yaml

@@ -280,7 +280,8 @@ startup:
     - harbor
   ignore_workload_namespaces: []
   ignore_workloads: []
-  ignore_unavailable_nodes: []
+  ignore_unavailable_nodes:
+    - titan-09
   auto_recycle_stuck_pods: true
   auto_quarantine_scheduling_storms: true
   scheduling_storm_event_threshold: 30

configs/ananke.titan-db.yaml

@@ -280,7 +280,8 @@ startup:
     - harbor
   ignore_workload_namespaces: []
   ignore_workloads: []
-  ignore_unavailable_nodes: []
+  ignore_unavailable_nodes:
+    - titan-09
   auto_recycle_stuck_pods: true
   auto_quarantine_scheduling_storms: true
   scheduling_storm_event_threshold: 30

internal/cluster/orchestrator_critical_vault.go

@@ -162,24 +162,35 @@ func (o *Orchestrator) waitWorkloadReady(ctx context.Context, w startupWorkload)
 		return o.waitVaultReady(ctx, w)
 	}
 
-	timeout := "240s"
-	if w.Kind == "statefulset" {
-		timeout = "360s"
-	}
+	deadline := time.Now().Add(7 * time.Minute)
+	var lastErr error
+	for time.Now().Before(deadline) {
+		o.bestEffort("recycle stuck critical workload pods", func() error { return o.recycleStuckControllerPods(ctx) })
 		_, err := o.kubectl(
 			ctx,
-		7*time.Minute,
+			45*time.Second,
 			"-n",
 			w.Namespace,
 			"rollout",
 			"status",
 			fmt.Sprintf("%s/%s", w.Kind, w.Name),
-		"--timeout="+timeout,
+			"--timeout=30s",
 		)
-	if err != nil {
-		return fmt.Errorf("wait ready %s/%s/%s: %w", w.Namespace, w.Kind, w.Name, err)
-	}
+		if err == nil {
 			return nil
+		}
+		lastErr = err
+
+		select {
+		case <-ctx.Done():
+			return ctx.Err()
+		case <-time.After(5 * time.Second):
+		}
+	}
+	if lastErr != nil {
+		return fmt.Errorf("wait ready %s/%s/%s: %w", w.Namespace, w.Kind, w.Name, lastErr)
+	}
+	return fmt.Errorf("wait ready %s/%s/%s: timeout", w.Namespace, w.Kind, w.Name)
 }
 
 // waitVaultReady runs one orchestration or CLI step.

internal/cluster/orchestrator_lifecycle.go

@@ -45,12 +45,17 @@ func (o *Orchestrator) Startup(ctx context.Context, opts StartupOptions) (err er
 	}
 	o.noteStartupCheck("node-inventory-reachability", true, "all expected nodes responded over SSH")
 	resumedFlux := false
+	allowFailedStartupFluxResume := false
 	defer func() {
 		if o.runner.DryRun || err == nil || resumedFlux {
 			return
 		}
-		o.log.Printf("warning: startup failed before normal flux resume; attempting best-effort recovery resume")
 		o.bestEffort("restore scaled workloads after failed startup", func() error { return o.restoreScaledApps(ctx) })
+		if !allowFailedStartupFluxResume {
+			o.log.Printf("warning: startup failed before recovery-safe flux resume; leaving flux suspension state unchanged")
+			return
+		}
+		o.log.Printf("warning: startup failed during flux resume; attempting best-effort recovery resume")
 		o.bestEffort("resume flux after failed startup", func() error { return o.resumeFluxAndReconcile(ctx) })
 	}()
 
@@ -292,6 +297,7 @@ func (o *Orchestrator) Startup(ctx context.Context, opts StartupOptions) (err er
 
 	o.noteStartupCheckState("flux-resume-reconcile", "running", "resuming flux and waiting for reconcile")
 	o.setStartupPhase("flux-resume", "resuming flux controllers and reconciling kustomizations")
+	allowFailedStartupFluxResume = true
 	if err := o.resumeFluxAndReconcile(ctx); err != nil {
 		o.noteStartupCheck("flux-resume-reconcile", false, err.Error())
 		return err

internal/cluster/orchestrator_unit_additional_test.go

@@ -8,6 +8,7 @@ import (
 	"net"
 	"path/filepath"
 	"strings"
+	"sync"
 	"testing"
 	"time"
 
@@ -73,6 +74,109 @@ func matchContains(cmd string, parts ...string) func(string, []string) bool {
 	}
 }
 
+// TestStartupEarlyFailureLeavesFluxSuspensionUnchanged runs one orchestration or CLI step.
+// Signature: TestStartupEarlyFailureLeavesFluxSuspensionUnchanged(t *testing.T).
+// Why: recovery must not release Flux when bootstrap fails before storage and
+// critical workloads are ready, or Flux can re-create the same dependency loop.
+func TestStartupEarlyFailureLeavesFluxSuspensionUnchanged(t *testing.T) {
+	tmpDir := t.TempDir()
+	cfg := config.Config{
+		SSHPort: 2277,
+		Startup: config.Startup{
+			APIWaitSeconds:              1,
+			APIPollSeconds:              1,
+			RequireNodeInventoryReach:   false,
+			RequireTimeSync:             false,
+			RequireNodeSSHAuth:          false,
+			ReconcileAccessOnBoot:       false,
+			AutoEtcdRestoreOnAPIFailure: false,
+			RequiredNodeLabels: map[string]map[string]string{
+				"titan-missing": {
+					"node-role.kubernetes.io/worker": "true",
+				},
+			},
+		},
+		State: config.State{
+			Dir:            tmpDir,
+			ReportsDir:     filepath.Join(tmpDir, "reports"),
+			RunHistoryPath: filepath.Join(tmpDir, "runs.json"),
+			LockPath:       filepath.Join(tmpDir, "ananke.lock"),
+			IntentPath:     filepath.Join(tmpDir, "intent.json"),
+		},
+	}
+
+	var mu sync.Mutex
+	calls := []string{}
+	orch := buildOrchestratorWithStubs(t, cfg, []commandStub{
+		{
+			match: func(name string, args []string) bool {
+				mu.Lock()
+				calls = append(calls, name+" "+strings.Join(args, " "))
+				mu.Unlock()
+				return false
+			},
+		},
+		{match: matchContains("kubectl", "version", "--request-timeout=5s"), out: "ok"},
+		{match: matchContains("kubectl", "-n", "vault", "get", "pod", "vault-0"), out: "Pending"},
+		{
+			match: matchContains("kubectl", "label", "node", "titan-missing"),
+			err:   errors.New(`nodes "titan-missing" not found`),
+		},
+	})
+
+	err := orch.Startup(context.Background(), StartupOptions{Reason: "test early failure"})
+	if err == nil {
+		t.Fatalf("expected startup to fail before flux resume")
+	}
+	if !strings.Contains(err.Error(), "ensure required node labels on titan-missing") {
+		t.Fatalf("expected required-label failure, got: %v", err)
+	}
+
+	mu.Lock()
+	defer mu.Unlock()
+	for _, call := range calls {
+		if strings.Contains(call, `"suspend":false`) {
+			t.Fatalf("early failed startup unexpectedly resumed flux via call: %s", call)
+		}
+	}
+}
+
+// TestRecycleStuckControllerPodsHandlesLonghornAttachBlockedPods runs one orchestration or CLI step.
+// Signature: TestRecycleStuckControllerPodsHandlesLonghornAttachBlockedPods(t *testing.T).
+// Why: Pending Longhorn-backed pods on Longhorn-unready nodes should be
+// rescheduled without mutating Longhorn volume, replica, or disk objects.
+func TestRecycleStuckControllerPodsHandlesLonghornAttachBlockedPods(t *testing.T) {
+	created := time.Now().Add(-10 * time.Minute).UTC().Format(time.RFC3339)
+	lastSeen := time.Now().UTC().Format(time.RFC3339)
+	pods := `{"items":[{"metadata":{"namespace":"monitoring","name":"victoria-metrics-single-server-0","creationTimestamp":"` + created + `","ownerReferences":[{"kind":"StatefulSet","name":"victoria-metrics-single-server"}]},"spec":{"nodeName":"titan-0b"},"status":{"phase":"Pending"}}]}`
+	events := `{"items":[{"metadata":{"namespace":"monitoring","creationTimestamp":"` + lastSeen + `"},"involvedObject":{"kind":"Pod","namespace":"monitoring","name":"victoria-metrics-single-server-0"},"type":"Warning","reason":"FailedAttachVolume","message":"AttachVolume.Attach failed for volume \"pvc-1\" : rpc error from [http://longhorn-backend:9500/v1/volumes/pvc-1?action=attach]: unable to attach volume pvc-1 to titan-0b: node titan-0b is not ready","lastTimestamp":"` + lastSeen + `"}]}`
+
+	deleted := false
+	orch := buildOrchestratorWithStubs(t, config.Config{
+		Startup: config.Startup{StuckPodGraceSeconds: 180},
+	}, []commandStub{
+		{match: matchContains("kubectl", "get", "pods", "-A", "-o", "json"), out: pods},
+		{match: matchContains("kubectl", "-n", "longhorn-system", "get", "nodes.longhorn.io"), out: "titan-0b\tFalse\n"},
+		{match: matchContains("kubectl", "get", "events", "-A", "-o", "json"), out: events},
+		{
+			match: func(name string, args []string) bool {
+				if !matchContains("kubectl", "-n", "monitoring", "delete", "pod", "victoria-metrics-single-server-0", "--wait=false")(name, args) {
+					return false
+				}
+				deleted = true
+				return true
+			},
+		},
+	})
+
+	if err := orch.recycleStuckControllerPods(context.Background()); err != nil {
+		t.Fatalf("recycleStuckControllerPods failed: %v", err)
+	}
+	if !deleted {
+		t.Fatalf("expected longhorn attach-blocked pending pod to be recycled")
+	}
+}
+
 // TestNewConstructsOrchestrator runs one orchestration or CLI step.
 // Signature: TestNewConstructsOrchestrator(t *testing.T).
 // Why: covers constructor path in orchestrator core module.

internal/cluster/orchestrator_workload_convergence.go

@@ -170,6 +170,12 @@ func (o *Orchestrator) recycleStuckControllerPods(ctx context.Context) error {
 		"CreateContainerConfigError": {},
 		"CreateContainerError":       {},
 	}
+	longhornAttachReasons := map[string]string{}
+	if reasons, scanErr := o.longhornAttachBlockedPodReasons(ctx, list, grace); scanErr != nil {
+		o.log.Printf("warning: longhorn attach-blocked pod scan failed: %v", scanErr)
+	} else {
+		longhornAttachReasons = reasons
+	}
 	recycled := []string{}
 	for _, pod := range list.Items {
 		ns := strings.TrimSpace(pod.Metadata.Namespace)
@@ -197,6 +203,9 @@ func (o *Orchestrator) recycleStuckControllerPods(ctx context.Context) error {
 		if reason == "" {
 			reason = stuckVaultInitReason(pod, grace)
 		}
+		if reason == "" {
+			reason = longhornAttachReasons[ns+"/"+name]
+		}
 		if reason == "" {
 			continue
 		}
@@ -215,6 +224,118 @@ func (o *Orchestrator) recycleStuckControllerPods(ctx context.Context) error {
 	return nil
 }
 
+// longhornAttachBlockedPodReasons runs one orchestration or CLI step.
+// Signature: (o *Orchestrator) longhornAttachBlockedPodReasons(ctx context.Context, pods podList, grace time.Duration) (map[string]string, error).
+// Why: after a power event, Kubernetes can schedule a Longhorn-backed pod onto a
+// node Longhorn still marks unready. Recycling the unattached Pending pod lets
+// the scheduler pick a Longhorn-ready node without touching Longhorn data-plane
+// objects.
+func (o *Orchestrator) longhornAttachBlockedPodReasons(ctx context.Context, pods podList, grace time.Duration) (map[string]string, error) {
+	unreadyNodes, err := o.longhornUnreadyNodes(ctx)
+	if err != nil {
+		return nil, err
+	}
+	if len(unreadyNodes) == 0 {
+		return map[string]string{}, nil
+	}
+
+	eventsOut, err := o.kubectl(ctx, 30*time.Second, "get", "events", "-A", "-o", "json")
+	if err != nil {
+		return nil, fmt.Errorf("query events for longhorn attach-blocked pod scan: %w", err)
+	}
+	var events eventList
+	if err := json.Unmarshal([]byte(eventsOut), &events); err != nil {
+		return nil, fmt.Errorf("decode events for longhorn attach-blocked pod scan: %w", err)
+	}
+
+	podsByKey := map[string]podResource{}
+	for _, pod := range pods.Items {
+		ns := strings.TrimSpace(pod.Metadata.Namespace)
+		name := strings.TrimSpace(pod.Metadata.Name)
+		node := strings.TrimSpace(pod.Spec.NodeName)
+		if ns == "" || name == "" || node == "" {
+			continue
+		}
+		if !strings.EqualFold(strings.TrimSpace(pod.Status.Phase), "Pending") {
+			continue
+		}
+		if _, unready := unreadyNodes[node]; !unready {
+			continue
+		}
+		if !podControllerOwned(pod) {
+			continue
+		}
+		if !pod.Metadata.CreationTimestamp.IsZero() && time.Since(pod.Metadata.CreationTimestamp) < grace {
+			continue
+		}
+		podsByKey[ns+"/"+name] = pod
+	}
+	if len(podsByKey) == 0 {
+		return map[string]string{}, nil
+	}
+
+	reasons := map[string]string{}
+	for _, event := range events.Items {
+		if !strings.EqualFold(strings.TrimSpace(event.Type), "Warning") {
+			continue
+		}
+		if strings.TrimSpace(event.Reason) != "FailedAttachVolume" {
+			continue
+		}
+		if !strings.EqualFold(strings.TrimSpace(event.InvolvedObject.Kind), "Pod") {
+			continue
+		}
+		key := strings.TrimSpace(event.InvolvedObject.Namespace) + "/" + strings.TrimSpace(event.InvolvedObject.Name)
+		pod, ok := podsByKey[key]
+		if !ok {
+			continue
+		}
+		lastSeen := eventLastObservedAt(event)
+		if !lastSeen.IsZero() && !pod.Metadata.CreationTimestamp.IsZero() && lastSeen.Before(pod.Metadata.CreationTimestamp) {
+			continue
+		}
+		node := strings.TrimSpace(pod.Spec.NodeName)
+		message := strings.ToLower(strings.TrimSpace(event.Message))
+		if !strings.Contains(message, "longhorn-backend") || !strings.Contains(message, "failed for volume") {
+			continue
+		}
+		if !strings.Contains(message, "node "+strings.ToLower(node)+" is not ready") {
+			continue
+		}
+		reasons[key] = "LonghornAttachBlockedOnUnreadyNode:" + node
+	}
+	return reasons, nil
+}
+
+// longhornUnreadyNodes runs one orchestration or CLI step.
+// Signature: (o *Orchestrator) longhornUnreadyNodes(ctx context.Context) (map[string]struct{}, error).
+// Why: Longhorn node readiness can lag or intentionally differ from Kubernetes
+// node readiness; attach recovery must use Longhorn's view for safety.
+func (o *Orchestrator) longhornUnreadyNodes(ctx context.Context) (map[string]struct{}, error) {
+	out, err := o.kubectl(ctx, 30*time.Second,
+		"-n", "longhorn-system",
+		"get", "nodes.longhorn.io",
+		"-o", "jsonpath={range .items[*]}{.metadata.name}{'\\t'}{range .status.conditions[?(@.type==\"Ready\")]}{.status}{end}{'\\n'}{end}",
+	)
+	if err != nil {
+		if isNotFoundErr(err) {
+			return map[string]struct{}{}, nil
+		}
+		return nil, fmt.Errorf("query longhorn node readiness: %w", err)
+	}
+	unready := map[string]struct{}{}
+	for _, line := range lines(out) {
+		fields := strings.Fields(line)
+		if len(fields) < 2 {
+			continue
+		}
+		if !strings.EqualFold(strings.TrimSpace(fields[1]), "True") {
+			unready[strings.TrimSpace(fields[0])] = struct{}{}
+		}
+	}
+	return unready, nil
+}
+
 // podControllerOwned runs one orchestration or CLI step.
 // Signature: podControllerOwned(p podResource) bool.
 // Why: keeps behavior explicit so startup/shutdown workflows remain maintainable as services evolve.