I've been using a RAID5 HDD storage (8x6TB) at my HP P840 for like 2 years now and it has always had unusually many drive failures. Everything was good for half a year, but now drives are failing in a strange way.
For example 2 new drives failed a few days after they have been added to the RAID.
I have also already replaced the RAID controller and am using up-to-date firmware on Mainboard and RAID controller.
Also I have tried to use different drives.
Initially there were HGST DeskStar 6TB drives used in that RAID, now I have been replacing them with HGST UltraStar 6TB when replacing failed drives. But the behaviour is the same.
Also it seems (most of) the drives are not really failed, because once I replaced the RAID controller, one failed drive was recognized as OK again and the rebuild started.
My hoster's support says the problem is that I'm actually using RAID5 and I should switch to RAID10 instead. It's hard for me to believe as I've been using RAID5 without problems at other systems (no drive failures in years).
Can anyone give me a hint, what else the culprit could be? Something wrong with the way the RAID controller is configured?
Thank you!
EDIT:
The server is a HP DL180 G9
Reason for drive failure is always "Write retries failed"
UPDATE: Our hoster offered us to completely replace the hardware and switch to RAID6. We did that and it's been running smoothly for a while now. Although this was not really investigated, I believe shodanshok's explanation about punctured arrays seems reasonable. Therefore I will accept that answer. Thanks everybody!
Smart Array P840 in Slot 1 (sn: PDNNF0ARH321GD)
Port Name: 1I
Port Name: 2I
Internal Drive Cage at Port 1I, Box 2, OK
Internal Drive Cage at Port 1I, Box 2, OK
Internal Drive Cage at Port 2I, Box 1, OK
array A (Solid State SATA, Unused Space: 0 MB)
logicaldrive 1 (447.1 GB, RAID 1+0, OK)
physicaldrive 2I:1:1 (port 2I:box 1:bay 1, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:2 (port 2I:box 1:bay 2, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:3 (port 2I:box 1:bay 3, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:4 (port 2I:box 1:bay 4, Solid State SATA, 240.0 GB, OK)
array B (SATA, Unused Space: 0 MB)
logicaldrive 2 (38.2 TB, RAID 5, Interim Recovery Mode)
physicaldrive 1I:2:1 (port 1I:box 2:bay 1, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:2 (port 1I:box 2:bay 2, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:3 (port 1I:box 2:bay 3, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:4 (port 1I:box 2:bay 4, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:5 (port 1I:box 2:bay 5, SATA, 6001.1 GB, Failed)
physicaldrive 1I:2:6 (port 1I:box 2:bay 6, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:7 (port 1I:box 2:bay 7, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:8 (port 1I:box 2:bay 8, SATA, 6001.1 GB, OK)
Detailed Info:
Smart Array P840 in Slot 1
Bus Interface: PCI
Slot: 1
Serial Number: PDNNF0ARH321GD
Cache Serial Number: PEYFP0BRH323YZ
RAID 6 (ADG) Status: Enabled
Controller Status: OK
Hardware Revision: B
Firmware Version: 6.60
Rebuild Priority: High
Expand Priority: Medium
Surface Scan Delay: 3 secs
Surface Scan Mode: Idle
Parallel Surface Scan Supported: Yes
Current Parallel Surface Scan Count: 1
Max Parallel Surface Scan Count: 16
Queue Depth: Automatic
Monitor and Performance Delay: 60 min
Elevator Sort: Enabled
Degraded Performance Optimization: Disabled
Inconsistency Repair Policy: Disabled
Wait for Cache Room: Disabled
Surface Analysis Inconsistency Notification: Disabled
Post Prompt Timeout: 15 secs
Cache Board Present: True
Cache Status: OK
Cache Ratio: 10% Read / 90% Write
Drive Write Cache: Enabled
Total Cache Size: 4.0 GB
Total Cache Memory Available: 3.2 GB
No-Battery Write Cache: Enabled
SSD Caching RAID5 WriteBack Enabled: True
SSD Caching Version: 2
Cache Backup Power Source: Batteries
Battery/Capacitor Count: 1
Battery/Capacitor Status: OK
SATA NCQ Supported: True
Spare Activation Mode: Activate on physical drive failure (default)
Controller Temperature (C): 51
Cache Module Temperature (C): 38
Number of Ports: 2 Internal only
Encryption: Disabled
Express Local Encryption: False
Driver Name: hpsa
Driver Version: 3.4.16
Driver Supports HP SSD Smart Path: True
PCI Address (Domain:Bus:Device.Function): 0000:06:00.0
Negotiated PCIe Data Rate: PCIe 3.0 x8 (7880 MB/s)
Controller Mode: RAID
Controller Mode Reboot: Not Required
Latency Scheduler Setting: Disabled
Current Power Mode: MaxPerformance
Host Serial Number: CZ270500GM
Sanitize Erase Supported: False
Primary Boot Volume: logicaldrive 1 (600508B1001CE0F9FACF3A1358647115)
Secondary Boot Volume: logicaldrive 1 (600508B1001CE0F9FACF3A1358647115)
Port Name: 1I
Port ID: 0
Port Connection Number: 0
SAS Address: 5001438038AD05A0
Port Location: Internal
Managed Cable Connected: False
Port Name: 2I
Port ID: 1
Port Connection Number: 1
SAS Address: 5001438038AD05A8
Port Location: Internal
Managed Cable Connected: False
Internal Drive Cage at Port 1I, Box 2, OK
Power Supply Status: Not Redundant
Drive Bays: 4
Port: 1I
Box: 2
Location: Internal
Physical Drives
physicaldrive 1I:2:1 (port 1I:box 2:bay 1, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:2 (port 1I:box 2:bay 2, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:3 (port 1I:box 2:bay 3, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:4 (port 1I:box 2:bay 4, SATA, 6001.1 GB, OK)
None attached
Internal Drive Cage at Port 1I, Box 2, OK
Power Supply Status: Not Redundant
Drive Bays: 4
Port: 1I
Box: 2
Location: Internal
Physical Drives
physicaldrive 1I:2:1 (port 1I:box 2:bay 1, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:2 (port 1I:box 2:bay 2, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:3 (port 1I:box 2:bay 3, SATA, 6001.1 GB, OK)
physicaldrive 1I:2:4 (port 1I:box 2:bay 4, SATA, 6001.1 GB, OK)
None attached
Internal Drive Cage at Port 2I, Box 1, OK
Power Supply Status: Not Redundant
Drive Bays: 4
Port: 2I
Box: 1
Location: Internal
Physical Drives
physicaldrive 2I:1:1 (port 2I:box 1:bay 1, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:2 (port 2I:box 1:bay 2, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:3 (port 2I:box 1:bay 3, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:4 (port 2I:box 1:bay 4, Solid State SATA, 240.0 GB, OK)
None attached
Array: A
Interface Type: Solid State SATA
Unused Space: 0 MB (0.0%)
Used Space: 894.2 GB (100.0%)
Status: OK
MultiDomain Status: OK
Array Type: Data
HP SSD Smart Path: disable
Logical Drive: 1
Size: 447.1 GB
Fault Tolerance: 1+0
Heads: 255
Sectors Per Track: 32
Cylinders: 65535
Strip Size: 256 KB
Full Stripe Size: 512 KB
Status: OK
MultiDomain Status: OK
Caching: Enabled
Unique Identifier: 600508B1001CE0F9FACF3A1358647115
Disk Name: /dev/sda
Mount Points: / 18.6 GB Partition Number 2
OS Status: LOCKED
Logical Drive Label: 0216D6F9PDNNF0ARH502MC7DFA
Mirror Group 1:
physicaldrive 2I:1:1 (port 2I:box 1:bay 1, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:2 (port 2I:box 1:bay 2, Solid State SATA, 240.0 GB, OK)
Mirror Group 2:
physicaldrive 2I:1:3 (port 2I:box 1:bay 3, Solid State SATA, 240.0 GB, OK)
physicaldrive 2I:1:4 (port 2I:box 1:bay 4, Solid State SATA, 240.0 GB, OK)
Drive Type: Data
LD Acceleration Method: Controller Cache
physicaldrive 2I:1:1
Port: 2I
Box: 1
Bay: 1
Status: OK
Drive Type: Data Drive
Interface Type: Solid State SATA
Size: 240.0 GB
Drive exposed to OS: False
Native Block Size: 4096
Firmware Revision: N2010101
Serial Number: PHDV712004AG240AGN
Model: ATA INTEL SSDSC2BB24
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 31
Maximum Temperature (C): 39
SSD Smart Trip Wearout: Not Supported
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 2I:1:2
Port: 2I
Box: 1
Bay: 2
Status: OK
Drive Type: Data Drive
Interface Type: Solid State SATA
Size: 240.0 GB
Drive exposed to OS: False
Native Block Size: 4096
Firmware Revision: N2010101
Serial Number: PHDV706303CH240AGN
Model: ATA INTEL SSDSC2BB24
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 29
Maximum Temperature (C): 36
SSD Smart Trip Wearout: Not Supported
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 2I:1:3
Port: 2I
Box: 1
Bay: 3
Status: OK
Drive Type: Data Drive
Interface Type: Solid State SATA
Size: 240.0 GB
Drive exposed to OS: False
Native Block Size: 4096
Firmware Revision: N2010101
Serial Number: PHDV712003V8240AGN
Model: ATA INTEL SSDSC2BB24
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 29
Maximum Temperature (C): 35
SSD Smart Trip Wearout: Not Supported
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 2I:1:4
Port: 2I
Box: 1
Bay: 4
Status: OK
Drive Type: Data Drive
Interface Type: Solid State SATA
Size: 240.0 GB
Drive exposed to OS: False
Native Block Size: 4096
Firmware Revision: N2010101
Serial Number: PHDV712004GA240AGN
Model: ATA INTEL SSDSC2BB24
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 31
Maximum Temperature (C): 37
SSD Smart Trip Wearout: Not Supported
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
Array: B
Interface Type: SATA
Unused Space: 0 MB (0.0%)
Used Space: 43.7 TB (100.0%)
Status: Failed Physical Drive
MultiDomain Status: OK
Array Type: Data
HP SSD Smart Path: disable
Warning: One of the drives on this array have failed or has been removed.
Logical Drive: 2
Size: 38.2 TB
Fault Tolerance: 5
Heads: 255
Sectors Per Track: 32
Cylinders: 65535
Strip Size: 256 KB
Full Stripe Size: 1792 KB
Status: Interim Recovery Mode
MultiDomain Status: OK
Caching: Enabled
Parity Initialization Status: Initialization Failed
Unique Identifier: 600508B1001CF94F84873C91FD89B549
Disk Name: /dev/sdb
Mount Points: None
Logical Drive Label: 04DA1DD6PDNNF0ARH502MC546F
Drive Type: Data
LD Acceleration Method: Controller Cache
physicaldrive 1I:2:1
Port: 1I
Box: 2
Bay: 1
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: APGNW7JH
Serial Number: NAHN3UZY
Model: ATA HGST HDN726060AL
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 37
Maximum Temperature (C): 43
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:2
Port: 1I
Box: 2
Bay: 2
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: APGNT517
Serial Number: NAHLKP0X
Model: ATA HGST HDN726060AL
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 37
Maximum Temperature (C): 56
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:3
Port: 1I
Box: 2
Bay: 3
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: T7MH
Serial Number: NCH8E81Z
Model: ATA HUS726060ALE610
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 33
Maximum Temperature (C): 41
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:4
Port: 1I
Box: 2
Bay: 4
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: APGNW7JH
Serial Number: NAHYMAUY
Model: ATA HGST HDN726060AL
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 34
Maximum Temperature (C): 41
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:5
Port: 1I
Box: 2
Bay: 5
Status: Failed
Last Failure Reason: Write retries failed
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: T7MH
Serial Number: K1H942MD
Model: ATA HUS726060ALE610
SATA NCQ Capable: True
SATA NCQ Enabled: True
Maximum Temperature (C): 43
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Applicable
Sanitize Erase Supported: False
physicaldrive 1I:2:6
Port: 1I
Box: 2
Bay: 6
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: TDR2
Serial Number: K8JM5TKN
Model: ATA HUS726060ALE610
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 33
Maximum Temperature (C): 38
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:7
Port: 1I
Box: 2
Bay: 7
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: APGNW7JH
Serial Number: K8H9BW2N
Model: ATA HGST HDN726060AL
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 34
Maximum Temperature (C): 39
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
physicaldrive 1I:2:8
Port: 1I
Box: 2
Bay: 8
Status: OK
Drive Type: Data Drive
Interface Type: SATA
Size: 6001.1 GB
Drive exposed to OS: False
Native Block Size: 4096
Rotational Speed: 7200
Firmware Revision: T7MH
Serial Number: K1H623JD
Model: ATA HUS726060ALE610
SATA NCQ Capable: True
SATA NCQ Enabled: True
Current Temperature (C): 35
Maximum Temperature (C): 40
PHY Count: 1
PHY Transfer Rate: 6.0Gbps
Drive Authentication Status: Not Authenticated. Smart Array will not control drive LEDs.
Sanitize Erase Supported: False
Best Answer
You probably have an heavily punctured array, which cause an early "planned death" of the replacement disk due to failed stripe reconstruction. You can read more information here and here
The solution is to backup, destroy the array, recreate it and restore from backup.
Next time avoid using a RAID5 array with such big drives. I strongly suggest using RAID6 or, even better, RAID10.