stack.basicstack.de/infrastructure/OS_UPDATE_PROCEDURE.md

# Weekly Rolling Ubuntu OS Update Procedure

**Purpose:** Keep every k3s node's Ubuntu OS patched (kernel, security, package updates) with a **rolling, zero-downtime** update — one node at a time, drain → update → reboot → verify → uncordon → cluster health check → next node.

**Audience:** Agents (currently CTO, optionally a dedicated ClusterOps agent). Also usable manually by an operator.

**Scope — what this procedure does:**
- Runs `apt-get update`, `apt-get -y upgrade`, `apt-get -y dist-upgrade`, `apt-get -y autoremove` on each cluster node.
- Reboots the node if a reboot is required (kernel/libc updates).
- Drains and cordons each node before touching it, uncordons after verification.
- Verifies the node and cluster are healthy before moving on.

**Scope — what this procedure MUST NOT do:**
- **Never change the Kubernetes / k3s setup.** Do not touch `/etc/systemd/system/k3s*.service*`, `/etc/rancher/k3s/*`, k3s binary version, k3s config, kube-system manifests, network policies, or any manifest under `infrastructure/`, `apps/`, or applied via ArgoCD.
- **Do not upgrade k3s** here. k3s upgrades are handled separately by system-upgrade-controller (see `K3S_OPERATIONS.md` and `k3s-upgrade/`).
- **Do not delete PersistentVolumes, PVCs, or workload manifests.**
- Do not "fix" application-level problems on a node — that's out of scope. Only fix problems in the OS/apt/reboot layer of the current node being updated. Anything else → stop, report, escalate.

---

## Cluster topology (context)

| Role | Node | Private IP | Public IP | Datacenter | Notes |
|------|------|-----------|-----------|------------|-------|
| control-plane | k3s-cp-1 | 10.42.1.1 | 178.105.17.239 | fsn1 | update LAST |
| worker | k3s-worker-1 | 10.42.1.2 | (via CP) | fsn1 | |
| worker | k3s-worker-2 | 10.42.1.3 | (via CP) | fsn1 | |
| worker | k3s-worker-3 | 10.42.1.5 | 167.233.121.121 | fsn1 | |
| worker | k3s-worker-4 | 10.42.1.6 | 128.140.3.80 | nbg1 | |
| worker | k3s-worker-5 | 10.42.1.7 | 167.233.192.86 | fsn1 | |
| runner | k3s-update-runner | 167.233.79.65 | 167.233.79.65 | fsn1 | k3s-upgrade helper, still an updatable node |

Always re-derive the live list before running — nodes may have been added/removed:

```bash
ssh root@178.105.17.239 'kubectl get nodes -o wide'
```

**Order rule:** update ALL workers first, control plane LAST. Within workers, update in this order to protect stateful workloads:
1. runner + workers that host no PVs (safest — lowest disruption)
2. remaining workers
3. **Stalwart-hosting fsn1 workers last among workers** — Stalwart has hard fsn1 affinity, so draining a fsn1 worker while another fsn1 worker is also unavailable can leave Stalwart Pending. Never have two fsn1 workers cordoned/down at the same time.
4. **k3s-cp-1 last** — single control plane; the API server goes away during its reboot.

**Concurrency:** exactly one node at a time. Never in parallel.

---

## Access

Prereqs are the same as `CLUSTER_ACCESS.md`:
- SSH key for `root` on every node (jump via control plane for private-IP workers).
- `kubectl` available (either from the operator machine, or by SSH-ing to the control plane and using it there).
- `hcloud` CLI configured (only needed for firewall-related recovery — not for normal runs).

Environment variables the scripts expect:
- `CONTROL_PLANE_HOST` — default `178.105.17.239`
- `CONTROL_PLANE_PRIVATE` — default `10.42.1.1`
- Drain timeout: `DRAIN_TIMEOUT_SECONDS` — default `600`
- Reboot wait: `REBOOT_MAX_WAIT_SECONDS` — default `600`
- Post-uncordon settle: `POST_UNCORDON_WAIT_SECONDS` — default `180`

---

## Preflight (run once per cycle, before touching any node)

1. **Cluster is currently healthy.** If any of the checks below fail, STOP and open an issue — do not start OS updates on an already-degraded cluster.
   ```bash
   ssh root@$CONTROL_PLANE_HOST bash -s <<'EOF'
   set -e
   kubectl get nodes
   echo "--- Not-ready nodes:"
   kubectl get nodes -o json | jq -r '.items[] | select(.status.conditions[] | select(.type=="Ready" and .status!="True")) | .metadata.name'
   echo "--- Pods not Running/Completed:"
   kubectl get pods -A --field-selector=status.phase!=Running,status.phase!=Succeeded | grep -v 'STATUS' || echo "  (none)"
   echo "--- Non-Ready pods (Running but not Ready):"
   kubectl get pods -A -o json | jq -r '.items[] | select(.status.phase=="Running") | select([.status.conditions[]?|select(.type=="Ready")|.status]|contains(["False"])) | "\(.metadata.namespace)/\(.metadata.name)"'
   EOF
   ```
   Only proceed if: all nodes `Ready`, no non-Running/Succeeded pods, no Running-but-not-Ready pods (small transient counts are OK — retry once and continue if it clears).

2. **Snapshot k3s datastore** (control plane only — this is a checkpoint you can restore etcd from if the control-plane reboot goes badly):
   ```bash
   ssh root@$CONTROL_PLANE_HOST 'k3s etcd-snapshot save --name pre-os-update-$(date +%Y%m%d)'
   ssh root@$CONTROL_PLANE_HOST 'k3s etcd-snapshot list | tail -5'
   ```

3. **List the nodes to update** and derive the ordered plan. Persist to `/tmp/os-update-plan.txt` on the control plane for auditability. See `scripts/os-update/os-update.sh` for the reference implementation of the ordering rule.

---

## Per-node procedure

Repeat for each node in the ordered plan. The reference implementation is `infrastructure/scripts/os-update/update-node.sh <node-name>`; the manual steps below are what that script does.

Throughout: every command's stdout+stderr goes to a per-run log at `/tmp/os-update-<node>-<timestamp>.log` on the control plane. Attach the log to the issue at the end.

### 1. Pre-check the node

```bash
NODE=<node-name>
kubectl get node "$NODE"
kubectl describe node "$NODE" | grep -A2 Conditions
```

Confirm: `Ready=True`, not already cordoned, no `DiskPressure`/`MemoryPressure`/`PIDPressure`.

### 2. Cordon and drain

```bash
kubectl cordon "$NODE"
kubectl drain "$NODE" \
  --ignore-daemonsets \
  --delete-emptydir-data \
  --disable-eviction=false \
  --timeout="${DRAIN_TIMEOUT_SECONDS:-600}s"
```

If drain fails on a PodDisruptionBudget:
- Do NOT force-delete pods (breaks HA guarantees).
- Log the blocking PDB, uncordon the node, mark the node as `SKIPPED_PDB` in the plan, and continue with the next node. Escalate the PDB conflict on the issue at the end.

If drain fails on a lone pod without a controller:
- Do NOT `--force`. Same as above — uncordon, mark `SKIPPED_ORPHAN_POD`, continue.

### 3. Update the OS

On the node itself:

```bash
ssh -o StrictHostKeyChecking=accept-new root@<node-ssh-target> bash -s <<'REMOTE'
set -euo pipefail
export DEBIAN_FRONTEND=noninteractive
# Refresh package lists
apt-get update
# Configure apt to keep existing config files silently (no interactive prompts)
APT_OPTS='-y -o Dpkg::Options::=--force-confdef -o Dpkg::Options::=--force-confold'
apt-get $APT_OPTS upgrade
apt-get $APT_OPTS dist-upgrade
apt-get $APT_OPTS autoremove --purge
apt-get clean
# Report reboot need
if [ -f /var/run/reboot-required ]; then
  echo "REBOOT_REQUIRED=yes"
  cat /var/run/reboot-required.pkgs 2>/dev/null || true
else
  echo "REBOOT_REQUIRED=no"
fi
REMOTE
```

For private-IP workers, target them from the control plane (`ssh -J root@$CONTROL_PLANE_HOST root@10.42.1.X`) or run the whole block after SSH-ing to the control plane first.

Common OS-only fixes the agent MAY perform on the node if apt fails:
- `dpkg --configure -a` after an interrupted install
- `apt-get -f install` to resolve broken deps
- Free disk with `journalctl --vacuum-time=3d` or `apt-get clean` if `/` is full
- Restart a system service that is stuck (`systemctl restart <unit>`) — but NOT `k3s`, `k3s-agent`, `containerd`, `flanneld`, or any container runtime

**Never**: change k3s config, delete PVs, uninstall packages the OS didn't schedule, edit `/etc/rancher/`, or reinstall k3s. If a fix would touch any of those, stop and escalate.

### 4. Reboot if required

If `REBOOT_REQUIRED=yes`:

```bash
ssh root@<node-ssh-target> 'systemctl reboot' || true
# Wait until SSH responds again (max REBOOT_MAX_WAIT_SECONDS)
deadline=$(( $(date +%s) + ${REBOOT_MAX_WAIT_SECONDS:-600} ))
while [ $(date +%s) -lt $deadline ]; do
  sleep 10
  if ssh -o ConnectTimeout=5 -o StrictHostKeyChecking=accept-new root@<node-ssh-target> 'uptime' 2>/dev/null; then
    echo "Node back up"; break
  fi
done
```

If the node doesn't come back within the timeout: escalate immediately. Do NOT rebuild the node or touch k3s — a rebuild requires the ADD_WORKER_NODE procedure and is a separate approved action.

### 5. Wait for k3s-agent / k3s to be ready again

```bash
# Wait for kubelet Ready condition (control plane view)
deadline=$(( $(date +%s) + 300 ))
while [ $(date +%s) -lt $deadline ]; do
  READY=$(kubectl get node "$NODE" -o jsonpath='{.status.conditions[?(@.type=="Ready")].status}')
  [ "$READY" = "True" ] && break
  sleep 5
done
kubectl get node "$NODE"
```

If Ready never returns True: escalate. Do NOT change k3s config.

### 6. Uncordon

```bash
kubectl uncordon "$NODE"
```

### 7. Post-node health verification

Wait for pods to reschedule and settle, then verify:

```bash
sleep "${POST_UNCORDON_WAIT_SECONDS:-180}"

# All nodes Ready?
kubectl get nodes
kubectl get nodes -o json | jq -r '.items[] | select(.status.conditions[] | select(.type=="Ready" and .status!="True")) | .metadata.name' | grep . && { echo "NOT-READY NODES"; exit 1; } || true

# Any pod not Running/Succeeded?
BAD=$(kubectl get pods -A --field-selector=status.phase!=Running,status.phase!=Succeeded --no-headers 2>/dev/null | wc -l)
[ "$BAD" -gt 0 ] && { echo "BAD PODS: $BAD"; kubectl get pods -A --field-selector=status.phase!=Running,status.phase!=Succeeded; exit 1; } || true

# Any Deployment/StatefulSet under desired replicas?
kubectl get deploy -A -o json | jq -r '.items[] | select((.status.readyReplicas // 0) < (.spec.replicas // 1)) | "deploy \(.metadata.namespace)/\(.metadata.name) \(.status.readyReplicas // 0)/\(.spec.replicas)"'
kubectl get sts -A -o json | jq -r '.items[] | select((.status.readyReplicas // 0) < (.spec.replicas // 1)) | "sts \(.metadata.namespace)/\(.metadata.name) \(.status.readyReplicas // 0)/\(.spec.replicas)"'
```

Only proceed to the next node when ALL of the above are green. If not:
- Give it another 3 minutes and re-check (workloads with large images may still be pulling).
- If still not green: STOP the cycle. Uncordon everything, leave the cluster in a stable state, and open a follow-up issue with the failing workloads. Do NOT proceed to update more nodes.

### 8. Control plane special handling

`k3s-cp-1` is the single control plane node. During its reboot:
- The kube-apiserver is unavailable — kubectl commands from the operator machine will error out.
- The `kubectl` waits in step 5/7 must run from a machine that is NOT the control plane, or must be scheduled after the control plane's SSH is back and `curl -k https://localhost:6443/healthz` returns `ok`.
- Skip the drain for DaemonSet pods on the control plane (`--ignore-daemonsets` covers that), but hosted apps that scheduled onto CP (rare — verify with `kubectl get pods -A --field-selector spec.nodeName=k3s-cp-1`) will be evicted.

---

## Finalization

After all nodes are done:

1. Final cluster health snapshot (same preflight commands as at the start).
2. Print apt history summary per node so the audit trail has "what changed":
   ```bash
   for host in <all-nodes>; do
     echo "=== $host ==="
     ssh root@$host 'zgrep -h "Commandline\|Install\|Upgrade\|Remove" /var/log/apt/history.log* 2>/dev/null | tail -60'
   done
   ```
3. Optional: prune old etcd snapshots to keep disk in check:
   ```bash
   ssh root@$CONTROL_PLANE_HOST 'k3s etcd-snapshot list'
   # delete anything older than 14 days if desired (manual review)
   ```
4. Attach the per-run logs to the Paperclip issue that triggered this run.
5. Update the issue with:
   - Nodes updated (list)
   - Nodes skipped (list + reason)
   - Any package that required manual intervention
   - Reboots performed
   - Final `kubectl get nodes` output

If everything is clean → mark the issue `done`.
If a node was skipped or errored → mark `blocked` with the unblock action, or open a child issue for the specific failure.

---

## Recovery / what to do when it goes wrong

**Node stuck cordoned after failure:** `kubectl uncordon <node>` — always leave the cluster back in its normal scheduling state.

**Node fails to boot after reboot:**
- Check Hetzner console for boot errors (kernel panic, initramfs).
- Try `hcloud server reboot <name>` from `hcloud` CLI.
- If the node cannot recover: escalate. Do NOT delete or rebuild the Hetzner server without board approval; that is the ADD_WORKER_NODE flow.

**k3s-agent won't start after reboot:**
- Check `journalctl -u k3s-agent -n 100`.
- Do NOT edit the k3s-agent unit file. Do NOT re-run the k3s installer.
- Escalate. This is out of scope for the OS-update procedure.

**Pods CrashLoopBackOff after node came back:**
- Not an OS-update problem to fix — the node is healthy, apt succeeded. Leave the node uncordoned, stop the cycle, and open an application-level issue.

**PDB blocked drain:**
- Never `--force` the drain. Leave the node uncordoned, skip it, note in the report which PDB blocked and which workload owns it.

**Datastore snapshot restore (last resort — CP only):**
- Only if the control plane is broken beyond repair. See `K3S_OPERATIONS.md` for the `--cluster-reset --cluster-reset-restore-path=<snapshot>` procedure. Requires board approval — do NOT execute unattended.

---

## Automation entry points

- `infrastructure/scripts/os-update/os-update.sh` — full cycle runner (preflight → per-node loop → finalization). Idempotent, resumable via `--start-from <node>`. Use `--dry-run` to print the plan without touching anything.
- `infrastructure/scripts/os-update/update-node.sh <node>` — single-node update (all 7 per-node steps). Callable standalone for retry.
- `infrastructure/scripts/os-update/cluster-health.sh` — the preflight/post-node health check as a standalone command; exits non-zero on any failure.

Read the script sources for the exact behavior before running them. They mirror this procedure step for step.

---

## Weekly schedule

A Paperclip routine (see `infrastructure/OS_UPDATE_ROUTINE.md`) fires this procedure once per week. The routine creates a task whose description points here. The assigned agent reads this document and executes the automation.

---

## Change history

| Date | Change | By |
|------|--------|-----|
| 2026-08-09 | Initial procedure + automation scripts | CTO agent (DEV-462) |