Adaptec 3210S, 4.9-STABLE, corruption when disk fails

From: Don Bowman (don_at_SANDVINE.com)
Date: 02/28/05

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    Date: Mon, 28 Feb 2005 16:58:26 -0500
To: <freebsd-stable@freebsd.org>

    I have a machine running:

    $ uname -a
    FreeBSD machine.phaedrus.sandvine.com 4.9-STABLE FreeBSD 4.9-STABLE #0:
    Fri Mar 19 10:39:07 EST 2004
    user@machine.phaedrus.sandvine.com:/usr/src/sys/compile/LABDB i386

    It has an adaptec 3210S raid controller running a single raid-5, and
    runs postgresql 7.4.6 as its primary application.

    3 times now I have had a drive fail, and have had corrupted files in the
    postgresql cluster @ the same time.

    The time is too closely correlated to be a coincidence. It passes fsck @
    the time that I got to it a couple of hours later, and the filesystem
    seems to be ok (with a failed drive, the raid in 'degrade' mode).

    It appears that the drive failure and the postgresql failure occur @
    exactly the same time (monitoring with nagios, within 1hr accuracy). It
    would appear that for some file(s) bad data was returned.

    Does anyone have any suggestions?

    $ raidutil -L all
    RAIDUTIL Version: 3.04 Date: 9/27/2000 FreeBSD CLI Configuration
    Utility
    Adaptec ENGINE Version: 3.04 Date: 9/27/2000 Adaptec FreeBSD SCSI
    Engine

    # b0 b1 b2 Controller Cache FW NVRAM Serial Status
    ------------------------------------------------------------------------ 

    ---
d0 -- --     ADAP3210S      16MB   370F  ADPT 1.0  BF0A21700J7Optimal
Physical View
Address    Type              Manufacturer/Model         Capacity  Status
------------------------------------------------------------------------
---
d0b0t0d0   Disk Drive (DASD) SEAGATE  ST318453LW        17501MB
Optimal
d0b0t1d0   Disk Drive (DASD) SEAGATE  ST318453LW        17501MB
Optimal
d0b0t2d0   Disk Drive (DASD) IBM      DNES-318350W      17501MB
Optimal
d0b1t3d0   Disk Drive (DASD) IBM      DNES-318350W      17501MB
Optimal
d0b1t4d0   Disk Drive (DASD) SEAGATE  ST318452LW        17501MB
Optimal
d0b1t5d0   Disk Drive (DASD) IBM      DNES-318350W      17501MB
Optimal
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