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I have the feeling this is a problem only showing up recently, e.g. again in https://openqa.opensuse.org/tests/1218912

[2020-03-30T13:59:52.476 CEST] [debug] running /usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/pool/7/openSUSE-13.1-gnome64.qcow2 /var/lib/openqa/pool/7/raid/hd0-overlay0 42949672960
[2020-03-30T13:59:52.497 CEST] [debug] Formatting '/var/lib/openqa/pool/7/raid/hd0-overlay0', fmt=qcow2 size=42949672960 backing_file=/var/lib/openqa/pool/7/openSUSE-13.1-gnome64.qcow2 cluster_size=65536 lazy_refcounts=off refcount_bits=16
[2020-03-30T13:59:52.497 CEST] [debug] running /usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/pool/7/openSUSE-Tumbleweed-NET-x86_64-Snapshot20200329-Media.iso /var/lib/openqa/pool/7/raid/cd0-overlay0 143654912
[2020-03-30T13:59:52.520 CEST] [debug] Formatting '/var/lib/openqa/pool/7/raid/cd0-overlay0', fmt=qcow2 size=143654912 backing_file=/var/lib/openqa/pool/7/openSUSE-Tumbleweed-NET-x86_64-Snapshot20200329-Media.iso cluster_size=65536 lazy_refcounts=off refcount_bits=16
[2020-03-30T13:59:52.521 CEST] [debug] Backend process died, backend errors are reported below in the following lines:
runcmd failed with exit code 1 at /usr/lib/os-autoinst/osutils.pm line 121.

I have one (related) idea for improvement. The error message could contain the command that failed. It's a best practice for log messages to be complete by themselves so we should not rely on any log messages that came in before.

https://github.com/os-autoinst/os-autoinst/pull/1391

I crosschecked if an error message from osutils would actually be shown. At least when running isotovideo -d locally in a shell on a simulated error condition I could see an error message clearly, e.g. I did

sudo chown root.root raid/
sudo chmod o-w raid/
isotovideo -d

which showed:

[2020-04-30T21:10:23.781 CEST] [debug] running /usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/share/factory/hdd/opensuse-Tumbleweed-x86_64-textmode@64bit.qcow2 …/raid/hd0-overlay0 0
[2020-04-30T21:10:23.796 CEST] [debug] qemu-img: …/raid/hd0-overlay0: Could not create file: Permission denied
Formatting '…/raid/hd0-overlay0', fmt=qcow2 size=0 backing_file=/var/lib/openqa/share/factory/hdd/opensuse-Tumbleweed-x86_64-textmode@64bit.qcow2 cluster_size=65536 lazy_refcounts=off refcount_bits=16
[2020-04-30T21:10:23.796 CEST] [debug] Backend process died, backend errors are reported below in the following lines:
runcmd '/usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/share/factory/hdd/opensuse-Tumbleweed-x86_64-textmode@64bit.qcow2 …/raid/hd0-overlay0 0' failed with exit code 1 at ../../osutils.pm line 122.

so the error message is shown. In the case of this ticket I could imagine either the stderr output is lost within openQA context or qemu-img actually fails silently with no output at all.

PR was merged and is deployed on o3. https://openqa.opensuse.org/tests/1251581 is one candidate that shows the same error with new output:

[2020-05-02T08:13:47.143 CEST] [debug] running /usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/pool/13/opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2 /var/lib/openqa/pool/13/raid/hd0-overlay0 32212254720
[2020-05-02T08:14:03.797 CEST] [debug] Formatting '/var/lib/openqa/pool/13/raid/hd0-overlay0', fmt=qcow2 size=32212254720 backing_file=/var/lib/openqa/pool/13/opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2 cluster_size=65536 lazy_refcounts=off refcount_bits=16
[2020-05-02T08:14:04.774 CEST] [debug] Backend process died, backend errors are reported below in the following lines:
runcmd '/usr/bin/qemu-img create -f qcow2 -b /var/lib/openqa/pool/13/opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2 /var/lib/openqa/pool/13/raid/hd0-overlay0 32212254720' failed with exit code 1 at /usr/lib/os-autoinst/osutils.pm line 121.

I have the journal from the worker machine from this time period attached mentioning the asset "opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2" multiple times.

Before the test starts I see:

May 02 08:11:32 openqa-aarch64 worker[2815]: [info] Download of opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2 processed:
May 02 08:11:32 openqa-aarch64 worker[2815]: [info] [#2713] Cache size of "/var/lib/openqa/cache" is 87GiB, with limit 200GiB
May 02 08:11:32 openqa-aarch64 worker[2815]: [info] [#2713] Downloading "opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2" from "http://openqa1-opensuse/tests/1251578/asset/hdd/opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2"
May 02 08:11:32 openqa-aarch64 worker[2815]: [info] [#2713] Content of "/var/lib/openqa/cache/openqa1-opensuse/opensuse-15.2-aarch64-159.1-textmode@aarch64.qcow2" has not changed, updating last use

so the file had been downloaded in before, it is just updated within the cache db. Also the cache has more than 100GiB free so no risk of exceeding the needed space.

After that there is

May 02 08:11:48 openqa-aarch64 worker[2823]: [info] 4028: WORKING 1251581
May 02 08:11:48 openqa-aarch64 worker[2817]: [info] 4027: WORKING 1251586
May 02 08:11:48 openqa-aarch64 worker[2819]: [info] 4031: WORKING 1251579
May 02 08:11:48 openqa-aarch64 worker[2815]: [info] Using cgroup /sys/fs/cgroup/systemd/openqa.slice/openqa-worker.slice/openqa-worker@6.service/1251578
May 02 08:11:48 openqa-aarch64 worker[2815]: [info] Starting isotovideo container
May 02 08:11:49 openqa-aarch64 worker[2815]: [info] isotovideo has been started (PID: 4037)
May 02 08:11:50 openqa-aarch64 worker[2815]: [info] 4037: WORKING 1251578
May 02 08:11:53 openqa-aarch64 worker[2818]: [info] 4023: WORKING 1251588
May 02 08:12:41 openqa-aarch64 nscd[1408]: 1408 monitored file `/etc/resolv.conf` changed (mtime)
May 02 08:12:41 openqa-aarch64 nscd[1408]: 1408 monitoring file `/etc/resolv.conf` (7)
May 02 08:12:41 openqa-aarch64 nscd[1408]: 1408 monitoring directory `/etc` (2)
May 02 08:14:55 openqa-aarch64 worker[2823]: [info] Isotovideo exit status: 1
May 02 08:14:57 openqa-aarch64 worker[2823]: [info] +++ worker notes +++
May 02 08:14:57 openqa-aarch64 worker[2823]: [info] End time: 2020-05-02 06:14:57

that is the current job 1251581 starting to work, other jobs and irrelevant entries and then the current job for the same worker (pid 2823) reporting the completion with failure. So no other output at all, no action within the cache at all, etc.

Other ideas I have: Run the qemu-img command with multiple retries or enable debugging and potentially parse the output file in case qemu-img fails. But I still have the suspicion that we are loosing output somewhere … Trying to add something with local tests.

https://github.com/os-autoinst/os-autoinst/pull/1392

Haven't found any jobs failing in the same step. So maybe we have the incompletes averted but struggle to find now where the retry is applied.

Looking for references in test results on o3:

/var/lib/openqa/testresults> ionice -c 3 find 0127* -type f -name autoinst-log.txt -exec grep 'init_blockdev_images.* failed' '{}' \;

EDIT: Found none. I will just check at a later time if there are any incompletes. If we do not find any I will assume that retries prevent the problem

With #64857 in place we can now more simply query the DB directly, e.g.

select jobs.id, t_started, workers.host as worker_host, workers.instance as worker_instance, reason from jobs join workers on assigned_worker_id=workers.id where result = 'incomplete' and reason ~ 'died.*qemu-img';

this currently yields a single job
https://openqa.opensuse.org/tests/1277401
which does not look like it applies the retries. For some reason it seems like we do not have that problem that often anymore. Let's give it some more days before checking again.

Checked o3 database again and have not found this problem again since 2020-05-25