raid10: 6 out of 8 disks marked as stale on every restart

[Peter Kieser <peter@kieser.ca>]

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Hello,

I have a 8 disk RAID10 array, 6 of the disks are on an LSISAS2008 
controller and 2 are on a  82801JI (ICH10 Family) SATA AHCI controller.  
I upgraded the kernel from 3.17.1 to 3.17.6 when the issue I am having 
started to occur, but reverting to an older kernel does not resolve the 
issue.

Restarting the machine causes the array not to start (or be visible in 
/proc/mdstat or any mention in kernel messages.) If I try to assemble 
the drives, mdraid complains that 6 out of the 8 disks (coincidentally 
all on the LSISAS2008 controller) are non-fresh:

root@kvm:~# mdadm --assemble /dev/md3 /dev/sde /dev/sdf /dev/sdg 
/dev/sdh /dev/sdi /dev/sdj /dev/sda /dev/sdb

Dec 11 21:08:25 kvm kernel: [  528.503736] md: kicking non-fresh sdi 
from array!
Dec 11 21:08:25 kvm kernel: [  528.503747] md: unbind<sdi>
Dec 11 21:08:25 kvm kernel: [  528.523775] md: export_rdev(sdi)
Dec 11 21:08:25 kvm kernel: [  528.523802] md: kicking non-fresh sdg 
from array!
Dec 11 21:08:25 kvm kernel: [  528.523809] md: unbind<sdg>
Dec 11 21:08:25 kvm kernel: [  528.531753] md: export_rdev(sdg)
Dec 11 21:08:25 kvm kernel: [  528.531780] md: kicking non-fresh sdf 
from array!
Dec 11 21:08:25 kvm kernel: [  528.531788] md: unbind<sdf>
Dec 11 21:08:25 kvm kernel: [  528.539749] md: export_rdev(sdf)
Dec 11 21:08:25 kvm kernel: [  528.539776] md: kicking non-fresh sdh 
from array!
Dec 11 21:08:25 kvm kernel: [  528.539785] md: unbind<sdh>
Dec 11 21:08:25 kvm kernel: [  528.547744] md: export_rdev(sdh)
Dec 11 21:08:25 kvm kernel: [  528.547771] md: kicking non-fresh sdj 
from array!
Dec 11 21:08:25 kvm kernel: [  528.547779] md: unbind<sdj>
Dec 11 21:08:25 kvm kernel: [  528.555755] md: export_rdev(sdj)
Dec 11 21:08:25 kvm kernel: [  528.555782] md: kicking non-fresh sde 
from array!
Dec 11 21:08:25 kvm kernel: [  528.555790] md: unbind<sde>
Dec 11 21:08:25 kvm kernel: [  528.563758] md: export_rdev(sde)
Dec 11 21:08:25 kvm kernel: [  528.565831] md/raid10:md3: not enough 
operational mirrors.
Dec 11 21:08:25 kvm kernel: [  528.567230] md: pers->run() failed ...

/dev/sda and /dev/sdb are the only drives not on the LSI controller. If 
I force the assembly with 6 out of the 8 drives the RAID array comes up:

root@kvm:~# mdadm --assemble /dev/md3 /dev/sde /dev/sdf /dev/sdg 
/dev/sdh /dev/sdi /dev/sdj --run

Then I add the extra drives:

root@kvm:~# mdadm --manage /dev/md3 --add /dev/sda
root@kvm:~# mdadm --manage /dev/md3 --add /dev/sdb

root@kvm:~# mdadm --detail /dev/md3
/dev/md3:
         Version : 1.0
   Creation Time : Thu Sep 12 18:43:56 2013
      Raid Level : raid10
      Array Size : 7814055936 (7452.06 GiB 8001.59 GB)
   Used Dev Size : 1953513984 (1863.02 GiB 2000.40 GB)
    Raid Devices : 8
   Total Devices : 8
     Persistence : Superblock is persistent

     Update Time : Fri Dec 12 08:58:19 2014
           State : active, degraded, recovering
  Active Devices : 6
Working Devices : 8
  Failed Devices : 0
   Spare Devices : 2

          Layout : near=2
      Chunk Size : 512K

  Rebuild Status : 76% complete

            Name : kvm.taylor.kieser.ca:3
            UUID : f0bc8469:9879a709:e4cc94a7:521bd273
          Events : 82901

     Number   Major   Minor   RaidDevice State
        0       8      128        0      active sync /dev/sdi
        8       8       96        1      active sync /dev/sdg
       11       8        0        2      spare rebuilding /dev/sda
        3       8      112        3      active sync /dev/sdh
        4       0        0        4      removed
       10       8       80        5      active sync /dev/sdf
        6       8       64        6      active sync /dev/sde
        9       8      144        7      active sync /dev/sdj

       12       8       16        -      spare   /dev/sdb

This occurs every time I restart the machine. Thoughts? I tried 
rebuilding the initramfs but this didn't resolve the issue. I'm also 
running bcache on this machine, but on top of the mdraid.

/etc/mdadm.conf:

# definitions of existing MD arrays
ARRAY /dev/md/0 metadata=1.0 UUID=3b174514:49f3e22e:550cf9a7:8ed93920 
name=linux:0
ARRAY /dev/md/1 metadata=1.0 UUID=8e23f81d:73f9b393:addd1f7f:5ee1833a 
name=linux:1
ARRAY /dev/md/2 metadata=1.0 UUID=cc5a0495:b5262855:fb3cd40a:8b237162 
name=kvm.taylor.kieser.ca:2
ARRAY /dev/md/3 metadata=1.0 UUID=f0bc8469:9879a709:e4cc94a7:521bd273 
name=kvm.taylor.kieser.ca:3


root@kvm:~# uname -a
Linux kvm 3.17.6 #3 SMP Sun Dec 7 12:16:45 PST 2014 x86_64 x86_64 x86_64 
GNU/Linux

root@kvm:~# mdadm -V
mdadm - v3.2.5 - 18th May 2012

root@kvm:~# cat /proc/mdstat
Personalities : [raid1] [linear] [multipath] [raid0] [raid6] [raid5] 
[raid4] [raid10]
md127 : inactive sdk[2](S)
       1465138448 blocks super 1.0

md3 : active raid10 sdb[12](S) sda[11] sdi[0] sdj[9] sde[6] sdf[10] 
sdh[3] sdg[8]
       7814055936 blocks super 1.0 512K chunks 2 near-copies [8/6] 
[UU_U_UUU]
       [===============>.....]  recovery = 76.6% (1498279040/1953513984) 
finish=4710.1min speed=1610K/sec

md1 : active raid1 sdd5[3] sdc5[2]
       25164672 blocks super 1.0 [2/2] [UU]

md0 : active raid1 sdd1[3] sdc1[2]
       16779136 blocks super 1.0 [2/2] [UU]

md2 : active raid1 sdd6[3] sdc6[2]
       192472960 blocks super 1.0 [2/2] [UU]

unused devices: <none>

-Peter



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