smom-dbis-138/docs/operations/status-reports/INFRASTRUCTURE_STATUS_EXPLANATION.md

Infrastructure Status - Detailed Explanation

Overview

Current Status: 1/25 clusters ready (4%) - Critical Infrastructure Issue

This document explains why 96% of clusters are in failed or canceled states and what needs to be done.

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Status Breakdown

✅ Ready Clusters: 1/25 (4%)

az-p-we-aks-main (West Europe)

• Status: Succeeded ✅
• Power State: Running
• Purpose: Administrative cluster (no validators/sentries)
• Note: This is the ONLY operational cluster, but it's intended for admin use only, not for validators

❌ Failed Clusters: 7/25 (28%)

All failed clusters are in a terminal error state and cannot be updated:

Cluster Name	Region	Power State	Issue
az-p-cc-aks-main	Canada Central	Deallocated	Stopped during update
az-p-fc-aks-main	France Central	Deallocated	Stopped during update
az-p-gwc-aks-main	Germany West Central	Deallocated	Stopped during update
az-p-noe-aks-main	Norway East	Deallocated	Stopped during update
az-p-sc-aks-main	Spain Central	Deallocated	Stopped during update
az-p-swc-aks-main	Sweden Central	Running	Failed but running
az-p-ukw-aks-main	UK West	Deallocated	Stopped during update

Root Cause: Terraform tried to update node pools while clusters were in a stopped state (Deallocated).

Error Message:

"Managed Cluster is in stopped state, no operations except for start are allowed."

What Happened:

1. Clusters were stopped (manually or due to resource issues)
2. Terraform attempted to update node pools
3. Azure rejected the operation because clusters were stopped
4. Clusters were marked as "Failed" and remained in Deallocated state

⚠️ Canceled Clusters: 16/25 (64%)

All canceled clusters are running but deployment was interrupted:

Clusters (16 total)	Power State	Issue
australiaeast, australiasoutheast, centralindia, eastasia, italynorth, japaneast, japanwest, koreacentral, koreasouth, mexicocentral, northeurope, polandcentral, southindia, southeastasia, switzerlandnorth, uksouth	Running	Deployment interrupted

Root Cause: Terraform deployment process was interrupted or canceled before completion.

What Happened:

1. Terraform started creating clusters
2. Deployment process was stopped/interrupted (timeout, cancellation, or error)
3. Clusters were created in Azure but deployment marked as "Canceled"
4. Clusters are running but not fully configured
5. Terraform state is out of sync - clusters exist in Azure but not in Terraform state

Evidence from Logs:

Error: A resource with the ID ".../az-p-ne-aks-main" already exists - 
to be managed via Terraform this resource needs to be imported into the State.

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Root Cause Analysis

Primary Issues

1. Stopped State Problem (Failed Clusters)

• Issue: Clusters were stopped during Terraform updates
• Impact: Terraform cannot update stopped clusters
• Frequency: 7 clusters affected (28%)
• Error: "Managed Cluster is in stopped state, no operations except for start are allowed"

Why This Happened:

• Clusters may have been stopped manually to save costs
• Clusters may have been stopped due to resource constraints
• Terraform attempted updates without checking cluster power state first

2. Deployment Interruption (Canceled Clusters)

• Issue: Terraform deployment was interrupted/canceled
• Impact: Clusters exist but are not in Terraform state
• Frequency: 16 clusters affected (64%)
• Error: "already exists - to be managed via Terraform this resource needs to be imported"

Why This Happened:

• Terraform process was killed or interrupted
• Deployment timeout
• Manual cancellation
• State lock issues
• Network issues during deployment

3. State Mismatch

• Issue: Terraform state does not match Azure reality
• Impact: Terraform cannot manage existing clusters
• Evidence:
  • 24 clusters exist in Azure
  • Only 7 clusters in Terraform state
  • 17 clusters need to be imported or deleted

4. Terraform Process Status

• Current: NOT RUNNING
• Last Activity: Stopped after encountering errors
• Log File: /tmp/terraform-apply-unlocked.log (316K, 4129 lines, 33 errors)

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Impact Assessment

What Works

✅ West Europe Admin Cluster: Fully operational (but admin-only) ✅ Infrastructure Foundation: Resource groups, networks, storage created (175 resource groups) ✅ Deployment Scripts: All scripts ready and tested ✅ Terraform Configuration: Configuration is correct, state is the issue

What Doesn't Work

❌ 24/25 Deployment Clusters: Failed or canceled (96% failure rate) ❌ Terraform State Management: Out of sync with Azure reality ❌ Cluster Deployment: Cannot proceed with validators/sentries ❌ Network Deployment: Cannot deploy Besu network

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Solution Path

Phase 1: Clean Up (Immediate)

Step 1: Delete Failed Clusters

Failed clusters in Deallocated state need to be deleted:

# Delete all failed clusters
az aks list --subscription fc08d829-4f14-413d-ab27-ce024425db0b \
  --query "[?contains(name, 'az-p-') && provisioningState == 'Failed'].{name:name, rg:resourceGroup}" \
  -o tsv | while IFS=$'\t' read -r name rg; do
    echo "Deleting $name..."
    az aks delete --name "$name" --resource-group "$rg" --yes --no-wait
done

Step 2: Handle Canceled Clusters

Two options for canceled clusters:

Option A: Import into Terraform State (Recommended if clusters are usable)

# Import canceled clusters into Terraform state
./scripts/deployment/import-existing-clusters.sh

Option B: Delete and Recreate (Recommended if clusters are incomplete)

# Delete canceled clusters
az aks list --subscription fc08d829-4f14-413d-ab27-ce024425db0b \
  --query "[?contains(name, 'az-p-') && provisioningState == 'Canceled'].{name:name, rg:resourceGroup}" \
  -o tsv | while IFS=$'\t' read -r name rg; do
    echo "Deleting $name..."
    az aks delete --name "$name" --resource-group "$rg" --yes --no-wait
done

Phase 2: Re-deploy (After Cleanup)

Step 3: Re-run Terraform

Once clusters are deleted, re-run Terraform:

cd terraform/well-architected/cloud-sovereignty
terraform apply -parallelism=128 -auto-approve

Expected Time: 30-60 minutes for all 24 clusters

Step 4: Monitor Progress

# Watch cluster creation
watch -n 30 'az aks list --query "[?contains(name, \"az-p-\")].{name:name, state:provisioningState}" -o table'

Phase 3: Verify and Continue (After Deployment)

Step 5: Verify All Clusters

./scripts/deployment/verify-all-clusters-parallel.sh

Step 6: Run Next Steps

Once all clusters are ready:

./scripts/deployment/run-next-steps-with-available.sh

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Why This Happened - Timeline

1. Initial Deployment: Terraform started creating 24 clusters across 24 regions
2. Interruption: Deployment was interrupted/canceled (likely timeout or manual cancellation)
3. Partial Success: Some clusters were created but not fully configured
4. State Loss: Terraform state became out of sync with Azure reality
5. Re-attempt: When Terraform was re-run, it found existing clusters and failed
6. Stopped Clusters: Some clusters were stopped (manually or automatically), causing update failures
7. Current State: 1 ready, 7 failed, 16 canceled

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Recommendations

Immediate Actions

1. Delete All Failed/Canceled Clusters

   • This is the cleanest approach
   • Allows fresh deployment
   • Eliminates state sync issues

2. Re-run Terraform Deployment

   • Start fresh deployment
   • Monitor closely for interruptions
   • Use proper timeout settings

3. Implement Deployment Monitoring

   • Monitor Terraform process
   • Set up alerts for failures
   • Prevent manual interruptions

Long-term Improvements

1. Prevent Cluster Stops

   • Add lifecycle rules to prevent accidental stops
   • Monitor cluster power state before updates
   • Implement auto-start for stopped clusters

2. Improve State Management

   • Use remote state backend
   • Implement state locking
   • Regular state validation

3. Better Error Handling

   • Check cluster power state before updates
   • Handle stopped clusters gracefully
   • Implement retry logic

4. Deployment Process

   • Use blue/green deployments for node pool updates
   • Implement deployment checkpoints
   • Add rollback capabilities

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Current Limitations

• 96% Cluster Failure Rate: Only 1/25 clusters operational
• No Validator Deployment: Cannot deploy Besu validators
• State Sync Issues: Terraform state out of sync
• Manual Cleanup Required: Cannot proceed without fixing cluster states

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Next Steps Priority

1. HIGH: Delete failed clusters (7 clusters)
2. HIGH: Delete or import canceled clusters (16 clusters)
3. HIGH: Re-run Terraform deployment
4. MEDIUM: Verify all clusters are ready
5. MEDIUM: Run next steps (Kubernetes, Besu, Contracts, Monitoring)

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Monitoring

• Terraform Log: /tmp/terraform-apply-unlocked.log
• Cluster Status: az aks list --query '[?contains(name, "az-p-")].{name:name, state:provisioningState}' -o table
• Dashboard: ./scripts/deployment/deployment-dashboard.sh

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Last Updated: 2025-11-14 Status: Critical - Requires immediate attention