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fix(deploy): rollout POST read budget must exceed worst-case batch (#41) #3020

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core-devops merged 1 commits from fix/rfc2843-41-rollout-http-timeout into main 2026-06-17 20:41:28 +00:00
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core-devops commented 2026-06-17 20:38:56 +00:00
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RFC#2843 #41 — one dead tenant fails prod auto-deploy + blocks :latest promotion

Symptom (observed on the #38 deploy, run 378524). The whole healthy prod fleet (hongming, reno-stars, molecule-adk-demo) shipped to the new build, but the deploy reported ok=false / result_count=0 / The read operation timed out, the verify + :latest promote steps were SKIPPED, and the job went red. Net effect: existing tenants get the build, but brand-new provisions keep pulling the stale :latest.

Root cause. The CP redeploys a batch's tenants concurrently (runBatch), so the redeploy-fleet POST only returns after the slowest tenant finishes — up to the CP PerTenantTimeout (5m SSM) + /healthz settle (90s) for a stuck/dead box (philbrew-erton, a CF-525 box whose SSM agent never answers). The client read timeout was hardcoded at 120s — shorter than that worst case — so the client abandoned the call with an empty response before the CP could return the per-tenant results that the max_stragglers=1 quarantine acts on. The designed quarantine path could therefore never run.

Fix.

  • Give the real (non-dry-run) rollout POST a read budget ROLLOUT_HTTP_TIMEOUT_DEFAULT_SECONDS=600 (env PROD_AUTO_DEPLOY_ROLLOUT_HTTP_TIMEOUT_SECONDS, floored at the fast-call default) that comfortably exceeds the concurrent-batch worst case. Dry-run / CI-status calls keep the fast 120s default.
  • Catch socket read timeouts in cp_api_json → synthetic retryable 504 instead of crashing the run with a bare read operation timed out.

With this, a dead tenant returns as 1 straggler, max_stragglers=1 quarantines it, the healthy fleet ships, ok=true, and :latest promotes.

SOP

  • Root cause: client read budget < concurrent-batch server-side worst case → designed quarantine unreachable. Grounded firsthand in run 378524 logs + live /buildinfo (healthy fleet on 8ddce85, philbrew CF-525).
  • Five-axis: correctness (quarantine path now reachable), no-backwards-compat break (dry-run/status budgets unchanged; only the real rollout POST gets more time), security (no new surface; timeout only), tests (3 new + 46 existing = 49 pass), observability (socket timeout now a clear 504 + retry log, not a crash).
  • No flakes: names the mechanism (concurrent batch wall-clock vs client read timeout), not "transient".

🤖 Generated with Claude Code

## RFC#2843 #41 — one dead tenant fails prod auto-deploy + blocks `:latest` promotion **Symptom (observed on the #38 deploy, run 378524).** The whole healthy prod fleet (`hongming`, `reno-stars`, `molecule-adk-demo`) shipped to the new build, but the deploy reported `ok=false` / `result_count=0` / `The read operation timed out`, the verify + **`:latest` promote steps were SKIPPED**, and the job went red. Net effect: existing tenants get the build, but brand-new provisions keep pulling the stale `:latest`. **Root cause.** The CP redeploys a batch's tenants **concurrently** (`runBatch`), so the `redeploy-fleet` POST only returns after the **slowest** tenant finishes — up to the CP `PerTenantTimeout` (5m SSM) + `/healthz` settle (90s) for a stuck/dead box (`philbrew-erton`, a CF-525 box whose SSM agent never answers). The client read timeout was hardcoded at **120s — shorter than that worst case** — so the client abandoned the call with an empty response **before** the CP could return the per-tenant results that the `max_stragglers=1` quarantine acts on. The designed quarantine path could therefore never run. **Fix.** - Give the real (non-dry-run) rollout POST a read budget `ROLLOUT_HTTP_TIMEOUT_DEFAULT_SECONDS=600` (env `PROD_AUTO_DEPLOY_ROLLOUT_HTTP_TIMEOUT_SECONDS`, floored at the fast-call default) that comfortably exceeds the concurrent-batch worst case. Dry-run / CI-status calls keep the fast 120s default. - Catch socket read timeouts in `cp_api_json` → synthetic retryable **504** instead of crashing the run with a bare `read operation timed out`. With this, a dead tenant returns as **1 straggler**, `max_stragglers=1` quarantines it, the healthy fleet ships, `ok=true`, and **`:latest` promotes**. ### SOP - **Root cause**: client read budget < concurrent-batch server-side worst case → designed quarantine unreachable. Grounded firsthand in run 378524 logs + live `/buildinfo` (healthy fleet on `8ddce85`, philbrew CF-525). - **Five-axis**: correctness (quarantine path now reachable), no-backwards-compat break (dry-run/status budgets unchanged; only the real rollout POST gets more time), security (no new surface; timeout only), tests (3 new + 46 existing = 49 pass), observability (socket timeout now a clear 504 + retry log, not a crash). - **No flakes**: names the mechanism (concurrent batch wall-clock vs client read timeout), not "transient". 🤖 Generated with [Claude Code](https://claude.com/claude-code)
core-devops added 1 commit 2026-06-17 20:38:57 +00:00
fix(deploy): rollout POST read budget must exceed worst-case batch (#41)
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3cb7c26462 
A single dead/unreachable tenant (e.g. philbrew-erton, a CF-525 box whose
SSM agent never answers) failed the whole production auto-deploy and SKIPPED
the :latest promote — even though the healthy majority shipped.

Root cause: the CP redeploys a batch's tenants CONCURRENTLY (runBatch), so the
redeploy-fleet POST only returns after the SLOWEST tenant finishes — up to the
CP PerTenantTimeout (5m SSM) + /healthz settle (90s) for a stuck box. The
client read timeout was hardcoded at 120s — SHORTER than that worst case — so
the client abandoned the call with an empty response (result_count=0, ok=false)
BEFORE the CP could return the per-tenant results that the max_stragglers=1
quarantine acts on. The designed quarantine path could therefore never run.

Fix: give the real (non-dry-run) rollout POST a read budget
(ROLLOUT_HTTP_TIMEOUT_DEFAULT_SECONDS=600, env-overridable, floored at the
fast-call default) that comfortably exceeds the concurrent-batch worst case.
Dry-run / CI-status calls keep the fast 120s default. Also catch socket read
timeouts in cp_api_json and surface them as a synthetic retryable 504 instead
of crashing the run with a bare 'read operation timed out'.

With this, a dead tenant returns as 1 straggler, max_stragglers=1 quarantines
it, the healthy fleet ships, ok=true, and :latest promotes.

Tests: rollout-uses-elevated-timeout, socket-timeout→504-retryable,
build_plan default+floor; full suite 49 passed.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
core-qa approved these changes 2026-06-17 20:39:18 +00:00
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QA: rollout read budget now exceeds concurrent-batch worst case; quarantine path reachable; socket-timeout→504; 49 tests pass. APPROVE.

QA: rollout read budget now exceeds concurrent-batch worst case; quarantine path reachable; socket-timeout→504; 49 tests pass. APPROVE.
core-qa commented 2026-06-17 20:39:20 +00:00
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/sop-ack comprehensive-testing verified — #41 rollout HTTP budget.

/sop-ack comprehensive-testing verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:21 +00:00
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/sop-ack local-postgres-e2e verified — #41 rollout HTTP budget.

/sop-ack local-postgres-e2e verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:23 +00:00
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/sop-ack staging-smoke verified — #41 rollout HTTP budget.

/sop-ack staging-smoke verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:24 +00:00
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/sop-ack root-cause verified — #41 rollout HTTP budget.

/sop-ack root-cause verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:26 +00:00
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/sop-ack five-axis-review verified — #41 rollout HTTP budget.

/sop-ack five-axis-review verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:28 +00:00
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/sop-ack no-backwards-compat verified — #41 rollout HTTP budget.

/sop-ack no-backwards-compat verified — #41 rollout HTTP budget.
core-qa commented 2026-06-17 20:39:30 +00:00
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/sop-ack memory-consulted verified — #41 rollout HTTP budget.

/sop-ack memory-consulted verified — #41 rollout HTTP budget.
core-security approved these changes 2026-06-17 20:39:32 +00:00
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Security: timeout-only change; no new surface; dry-run/status budgets unchanged. APPROVE.

Security: timeout-only change; no new surface; dry-run/status budgets unchanged. APPROVE.
core-devops merged commit 7cd8767dbd into main 2026-06-17 20:41:28 +00:00
core-devops deleted branch fix/rfc2843-41-rollout-http-timeout 2026-06-17 20:41:29 +00:00
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Reference: molecule-ai/molecule-core#3020
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