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pg_standby stuck on a wal file size <16MB

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I've been having problem with pgsql-8.2.5 master/slave warm standby replication setup where occasionally master node generates a wal file smaller then expected 16MB. pg_standby on slave gets stuck on such short files, and replication halts from that moment on. we have to do pg_start_backup/ rsync of data to slave / pg_stop_backup and restart slave in order to recover. database I'm replicating is write mostly.

this is process on slave that is waiting on log file which is smaller in size: postgres 14277 11857 0 03:34 ? 00:00:00 sh -c /usr/local/pgsql/bin/pg_standby -d -k 255 -r 7 -s 10 -w 0 -t /usr/local/recovery_control/quit_recovery /usr/local/wal_archive 000000010000034000000020 pg_xlog/RECOVERYXLOG 2>> /usr/local/pgsql/data/standby.log postgres 14278 14277 0 03:34 ? 00:00:00 /usr/local/pgsql/bin/pg_standby -d -k 255 -r 7 -s 10 -w 0 -t /usr/local/recovery_control/quit_recovery /usr/local/wal_archive 000000010000034000000020 pg_xlog/RECOVERYXLOG

here is a sample list of wal_archive directory slave, note the size of 000000010000034000000020 expected wal file is less then 16MB:

...
-rw------- 1 postgres postgres 16777216 May 17 03:19 000000010000034000000017 -rw------- 1 postgres postgres 16777216 May 17 03:21 000000010000034000000018 -rw------- 1 postgres postgres 16777216 May 17 03:22 000000010000034000000019 -rw------- 1 postgres postgres 16777216 May 17 03:24 00000001000003400000001A -rw------- 1 postgres postgres 16777216 May 17 03:26 00000001000003400000001B -rw------- 1 postgres postgres 16777216 May 17 03:27 00000001000003400000001C -rw------- 1 postgres postgres 16777216 May 17 03:29 00000001000003400000001D -rw------- 1 postgres postgres 16777216 May 17 03:30 00000001000003400000001E -rw------- 1 postgres postgres 16777216 May 17 03:32 00000001000003400000001F

-rw------- 1 postgres postgres 13746176 May 17 03:34 000000010000034000000020

-rw------- 1 postgres postgres 16777216 May 17 03:35 000000010000034000000021 -rw------- 1 postgres postgres 16777216 May 17 03:37 000000010000034000000022 -rw------- 1 postgres postgres 16777216 May 17 03:38 000000010000034000000023 -rw------- 1 postgres postgres 16777216 May 17 03:40 000000010000034000000024 -rw------- 1 postgres postgres 16777216 May 17 03:41 000000010000034000000025 -rw------- 1 postgres postgres 16777216 May 17 03:43 000000010000034000000026 -rw------- 1 postgres postgres 16777216 May 17 03:45 000000010000034000000027
...

skipping a bit further I see there is at least one other instance where wal file is shorter then normal 16MB:

-rw------- 1 postgres postgres 16777216 May 17 05:42 00000001000003400000006F -rw------- 1 postgres postgres 16777216 May 17 05:44 000000010000034000000070 -rw------- 1 postgres postgres 16777216 May 17 05:46 000000010000034000000071 -rw------- 1 postgres postgres 16777216 May 17 05:47 000000010000034000000072

-rw------- 1 postgres postgres 16384 May 17 05:50 000000010000034000000073

-rw------- 1 postgres postgres 16777216 May 17 05:51 000000010000034000000074 -rw------- 1 postgres postgres 16777216 May 17 05:52 000000010000034000000075 -rw------- 1 postgres postgres 16777216 May 17 05:54 000000010000034000000076

why would a master node create a wal file smaller then normal checkpoint_segment size and how can this be avoided. I need a reliable replication mechanism even at a cost of longer recovery on standby.

master's postgresql.conf:
..
fsync = on
wal_sync_method = open_sync
wal_buffers = 128
checkpoint_segments = 64
archive_command = 'test ! -f /usr/local/wal_archive_local/%f && cp %p /usr/local/wal_archive_local/%f'

archive files are then moved  on master to standby every other minute:

rsync -aq --remove-sent-files /usr/local/wal_archive_local/ slave::wal_archive/

slave's recovery.conf:
restore_command = '/usr/local/pgsql/bin/pg_standby -d -k 255 -r 7 -s 10 -w 0 -t /usr/local/recovery_control/quit_recovery /usr/local/wal_archive %f %p 2>> /u
sr/local/pgsql/data/standby.log'

both servers are identical Dell PE1950 servers with 4 sas hd w/hardware RAID 1+0 running: 2.6.18-8.1.8.el5 #1 SMP Tue Jul 10 06:39:17 EDT 2007 x86_64 x86_64 x86_64 GNU/Linux

Thanks much in advance
V.


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