bad block on 3ware array

dougs

dougs

Received this email from one of my servers:

Code: 
This message was generated by the smartd daemon running on:

   host name:  pisces
   DNS domain: example.com

The following warning/error was logged by the smartd daemon:

Device: /dev/twa0 [3ware_disk_00], ATA error count increased from 0 to 1

Device info:
WDC WD7500AYYS-01RCA0, S/N:WD-WCAPT0349997, WWN:5-0014ee-2ab2c4ece, FW:30.04G30, 750 GB

For details see host's SYSLOG.

You can also use the smartctl utility for further investigation.
No additional messages about this problem will be sent.

Okay, so I have a bad block somewhere on disk0 of the 3ware array.

Code: 
root@pisces:/# smartctl -a /dev/twa0 -d 3ware,0
smartctl 6.2 2013-07-26 r3841 [FreeBSD 9.1-RELEASE-p10 i386] (local build)
Copyright (C) 2002-13, Bruce Allen, Christian Franke, www.smartmontools.org

=== START OF INFORMATION SECTION ===
Model Family:     Western Digital RE2 Serial ATA
Device Model:     WDC WD7500AYYS-01RCA0
Serial Number:    WD-WCAPT0349997
LU WWN Device Id: 5 0014ee 2ab2c4ece
Firmware Version: 30.04G30
User Capacity:    750,156,374,016 bytes [750 GB]
Sector Size:      512 bytes logical/physical
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   ATA/ATAPI-7 (minor revision not indicated)
Local Time is:    Tue Jan 28 12:48:50 2014 PST
SMART support is: Available - device has SMART capability.
SMART support is: Enabled

=== START OF READ SMART DATA SECTION ===
SMART overall-health self-assessment test result: PASSED

General SMART Values:
Offline data collection status:  (0x05) Offline data collection activity
                                        was aborted by an interrupting command from host.
                                        Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0) The previous self-test routine completed
                                        without error or no self-test has ever 
                                        been run.
Total time to complete Offline 
data collection:                (15960) seconds.
Offline data collection
capabilities:                    (0x7b) SMART execute Offline immediate.
                                        Auto Offline data collection on/off support.
                                        Suspend Offline collection upon new
                                        command.
                                        Offline surface scan supported.
                                        Self-test supported.
                                        Conveyance Self-test supported.
                                        Selective Self-test supported.
SMART capabilities:            (0x0003) Saves SMART data before entering
                                        power-saving mode.
                                        Supports SMART auto save timer.
Error logging capability:        (0x01) Error logging supported.
                                        General Purpose Logging supported.
Short self-test routine 
recommended polling time:        (   2) minutes.
Extended self-test routine
recommended polling time:        ( 198) minutes.
Conveyance self-test routine
recommended polling time:        (   6) minutes.
SCT capabilities:              (0x303f) SCT Status supported.
                                        SCT Error Recovery Control supported.
                                        SCT Feature Control supported.
                                        SCT Data Table supported.

SMART Attributes Data Structure revision number: 16
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAG     VALUE WORST THRESH TYPE      UPDATED  WHEN_FAILED RAW_VALUE
  1 Raw_Read_Error_Rate     0x000f   200   200   051    Pre-fail  Always       -       0
  3 Spin_Up_Time            0x0003   207   184   021    Pre-fail  Always       -       6633
  4 Start_Stop_Count        0x0032   100   100   000    Old_age   Always       -       49
  5 Reallocated_Sector_Ct   0x0033   192   192   140    Pre-fail  Always       -       60
  7 Seek_Error_Rate         0x000e   198   198   051    Old_age   Always       -       22
  9 Power_On_Hours          0x0032   030   030   000    Old_age   Always       -       51115
 10 Spin_Retry_Count        0x0012   100   253   051    Old_age   Always       -       0
 11 Calibration_Retry_Count 0x0012   100   253   051    Old_age   Always       -       0
 12 Power_Cycle_Count       0x0032   100   100   000    Old_age   Always       -       46
192 Power-Off_Retract_Count 0x0032   200   200   000    Old_age   Always       -       426
193 Load_Cycle_Count        0x0032   200   200   000    Old_age   Always       -       428
194 Temperature_Celsius     0x0022   114   101   000    Old_age   Always       -       38
196 Reallocated_Event_Count 0x0032   172   172   000    Old_age   Always       -       28
197 Current_Pending_Sector  0x0012   200   200   000    Old_age   Always       -       1
198 Offline_Uncorrectable   0x0010   200   200   000    Old_age   Offline      -       0
199 UDMA_CRC_Error_Count    0x003e   200   200   000    Old_age   Always       -       0
200 Multi_Zone_Error_Rate   0x0008   200   200   051    Old_age   Offline      -       0

SMART Error Log Version: 1
No Errors Logged

SMART Self-test log structure revision number 1
Num  Test_Description    Status                  Remaining  LifeTime(hours)  LBA_of_first_error
# 1  Extended offline    Completed without error       00%     50951         -
# 2  Extended offline    Completed: read failure       90%     50939         106612099
# 3  Extended offline    Completed without error       00%     50774         -
# 4  Extended offline    Completed without error       00%     50606         -
# 5  Extended offline    Completed without error       00%     50438         -
# 6  Extended offline    Completed without error       00%     50270         -
# 7  Extended offline    Completed without error       00%     50103         -
# 8  Extended offline    Completed without error       00%     49935         -
# 9  Extended offline    Completed without error       00%     49767         -
#10  Extended offline    Completed without error       00%     49600         -
#11  Extended offline    Completed without error       00%     49432         -
#12  Extended offline    Completed without error       00%     49264         -
#13  Extended offline    Completed without error       00%     49096         -
#14  Extended offline    Completed without error       00%     48927         -
#15  Extended offline    Completed without error       00%     48760         -
#16  Extended offline    Completed without error       00%     48592         -
#17  Extended offline    Completed without error       00%     48424         -
#18  Extended offline    Completed without error       00%     48256         -
#19  Extended offline    Completed without error       00%     48089         -
#20  Extended offline    Completed without error       00%     47921         -
#21  Extended offline    Completed without error       00%     47753         -
1 of 1 failed self-tests are outdated by newer successful extended offline self-test # 1

SMART Selective self-test log data structure revision number 1
 SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Not_testing
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

root@pisces:/#

Ah, the bad block is at LBA 106612099! Need a bit more info:

Code: 
root@pisces:/# diskinfo -v da0
da0
        512             # sectorsize
        2197949513216   # mediasize in bytes (2T)
        4292870143      # mediasize in sectors
        0               # stripesize
        0               # stripeoffset
        267218          # Cylinders according to firmware.
        255             # Heads according to firmware.
        63              # Sectors according to firmware.
        T0349997CC0B5000EB8E    # Disk ident.
root@pisces:/root#

Okay, so all sectors are sized 512 bytes. More info:

Code: 
root@pisces:/# gpart show
=>        63  4292870080  da0  MBR  (2T)
          63  4292869329    1  freebsd  [active]  (2T)
  4292869392         751       - free -  (375k)

=>         0  4292869329  da0s1  BSD  (2T)
           0     1048576      1  freebsd-ufs  (512M)
     1048576     8310592      2  freebsd-swap  (4G)
     9359168     6250496      4  freebsd-ufs  (3G)
    15609664     1048576      5  freebsd-ufs  (512M)
    16658240    18628608      6  freebsd-ufs  (8.9G)
    35286848  4257582481      7  freebsd-ufs  (2T)

=>       63  101595074  da1  MBR  (48G)
         63  101594997    1  freebsd  [active]  (48G)
  101595060         77       - free -  (38k)

=>        0  101594997  da1s1  BSD  (48G)
          0  101594997      4  freebsd-ufs  (48G)

root@pisces:/# df
Filesystem  1K-blocks        Used     Avail Capacity  Mounted on
/dev/da0s1a     507630     266638    200382    57%    /
devfs                1          1         0   100%    /dev
/dev/da0s1g 2061818022 1271149146 625723436    67%    /backup
/dev/da1s1d   49199012   37754490   7508602    83%    /home
/dev/da0s1e     507630        108    466912     0%    /tmp
/dev/da0s1f    9018222    3753794   4542972    45%    /usr
/dev/da0s1d    3024526    1947222    835342    70%    /var
root@pisces:/#

So the bad block is on /dev/da0s1g.

Reading off a post at http://forums.freenas.org/threads/fix-bad-blocks.3708/, it looks like I need to do a 'dd':

Code: 
root@pisces:/# dd bs=512 seek=106612099 if=/dev/zero of=/dev/twa0 -d 3ware,0 count=1
dd: unknown operand -d
root@pisces:/# dd bs=512 seek=106612099 if=/dev/zero of=/dev/3ware,0 count=1        
dd: /dev/3ware,0: Operation not supported
root@pisces:/# dd bs=512 seek=106612099 if=/dev/zero of=/dev/da0 count=1      
dd: /dev/da0: Operation not permitted
root@pisces:/# dd bs=512 seek=106612099 if=/dev/zero of=/dev/da0s7 count=1
dd: /dev/da0s7: Operation not supported
root@pisces:/# dd bs=512 seek=106612099 if=/dev/zero of=/dev/da0s1g count=1 
dd: /dev/da0s1g: Operation not permitted
root@pisces:/#

Code: 
root@pisces:/# uname -a
FreeBSD pisces.dawnsign.com 9.1-RELEASE-p10 FreeBSD 9.1-RELEASE-p10 #0: Sun Jan 12 10:32:09 UTC 2014     root@amd64-builder.daemonology.net:/usr/obj/usr/src/sys/GENERIC  i386
root@pisces:/#

Do I need to take this drive offline- i.e. reboot into safe mode and boot up using a LiveCD and go into shell and perform a dd? I want to make sure I don't overwrite any data or lose it some other way! What's the best way to repair this particular sector? This is the first bad sector I've seen on this server and it's been running since 2007!

~Doug
 
Use either the tw_cli utility or the 3dmd/3dm2 web interface and run a Verifiy opteration. That will detect the bad block and re-write it to a working sector. No dd required.

In fact, just configure the controller to run an automatic verify process on a regular schedule.
 
Yeah, I saw the sysutils/3dm port and also the sysutils/tw_cli port. I installed them both and from the local 3dm2 website, I ran the verify process. It took a couple hours and here are the results:

Code: 
pisces.<redacted>.<redacted> kernel log messages:
+++ /tmp/security.oBQRqGHs	2014-01-31 03:02:23.000000000 -0800
+twa0: INFO: (0x04: 0x0029): Verify started: unit=0
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x3B0F4
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x54458
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x199BE8
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x319700
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x32CD26
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x476902
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x47FD40
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x49DD9D
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x7601E5
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0xBA23E1
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x113E7BB
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x129ED6B
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x140C774
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x1436ACC
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x1F67B49
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x2259470
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x23B2A51
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x23C99AC
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x2AE54B1
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x2F43974
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x3231AC6
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x336CB11
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x37C7B9D
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x3BFAD31
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x3D7CBEC
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x3EE3E93
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x403D063
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x4055C1A
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x41CAE13
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x41D1E8E
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x4336A2E
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x5E470AA
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x5E4E775
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x69E5BC4
+twa0: WARNING: (0x04: 0x0023): Sector repair completed: port=0, LBA=0x6C803BC
+twa0: INFO: (0x04: 0x002B): Verify completed: unit=0

35 bad sectors. Doesn't look good. I'm going to do another verify after this weekend and if that comes up with more bad sectors, I'm going to replace that drive!

Thanks for the pointers!

~Doug
 
Above, It said 60 bad blocks have already been remapped:
Code: 
5 Reallocated_Sector_Ct   0x0033   192   192   140    Pre-fail  Always       -       60
 
Can I ask a really dumb question: What RAID level are you running on that array?

If it is a redundant level (RAID 1 or larger), then you really have no problem. You have one disk in the array that has errors, and it seems that the array has already remapped that data elsewhere. In that case, you need to tell the array to remove that failing drive (after you identify it with 3Ware specific tools), put a new spare disk in, and let the array rebuild its redundancy.

If it a non-redundant level (RAID 0, sometimes also just called "striping", I'm not familiar with 3Ware's user interface), then you have real data errors. But then, why are you overwriting them with dd? What good can this possibly do? Your physical disks are behind a RAID controller. It's not your job to diagnose the health of the disks themselves; leave that to the controller, who can speak to the disks directly. I would start the opposite way: first find out whether they are now OK or not, by using dd to read them. You may very well find that data has already been lost, and that the disk sectors are now readable, but happen to return wrong data. In that case, the real task is finding out where in the file system these blocks are mapped.

I would allow the 3Ware controller to do all the repair and verify it can do, before proceeding any further, just like phoenix said.
 
ralphbsz said:
Can I ask a really dumb question: What RAID level are you running on that array?

If it is a redundant level (RAID 1 or larger), then you really have no problem. You have one disk in the array that has errors, and it seems that the array has already remapped that data elsewhere. In that case, you need to tell the array to remove that failing drive (after you identify it with 3Ware specific tools), put a new spare disk in, and let the array rebuild its redundancy.
Click to expand...

It's a RAID5 array and, yes, I do plan on replacing the failing drive using the 3dm2 tools.

~Doug
 
I would probably replace the drive. While many of my older RE2 or RE3 drives (50,000+ hours) have one or two remapped sectors, 60 (plus 35 new, if I understand correctly) is on the high side and might indicate a drive on the brink of failure.
 
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