My md won't assemble even when disks are in clean state.

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Hi,

Today my host had a power outage due to user mistake in the middle of a disk replacement. The replacement was simply to replace an old/smaller disk with new/larger one. No drive had failed prior to replacement. My /dev/md0 is a RAID6 with 6 disks prior to replacement (sd{b,c,e,f,g,h}1) I started replacement with this following commands

1. mdadm /dev/md0 --add /dev/sdi1
2. echo want-replacement > /sys/block/md0/md/dev-sdg1/state

It was going to take about 6hr for the rebuild to complete. Then the power outage happened about 1hr in to the replacement. On reboot the array has all 7 (old 6+new 1) as spares and failed to assemble. The disk names have also changed which did not surprise me. mdadm --assemble -force did not work. It reported that all spares are busy. I suspect that it has 7 disk for 6 array raid6 and does not know which 6 to pick to bring up the array. Looking at the disk vendor and serial numbers, I think the replacement is /dev/sdf1 and the one getting replaced is /dev/sdi1 in the following details (Note that pre crash this was called /dev/sdg1)

   zym [root] 27 > mdadm --version
   mdadm - v3.2.5 - 18th May 2012

   zym [root] 28 > uname -a
   Linux zym 3.13.0-106-generic #153-Ubuntu SMP Tue Dec 6 15:44:32 UTC
   2016 x86_64 x86_64 x86_64 GNU/Linux

   zym [root] 29 > cat /etc/os-release
   NAME="Ubuntu"
   VERSION="14.04.5 LTS, Trusty Tahr"
   ID=ubuntu
   ID_LIKE=debian
   PRETTY_NAME="Ubuntu 14.04.5 LTS"
   VERSION_ID="14.04"
   HOME_URL="http://www.ubuntu.com/";
   SUPPORT_URL="http://help.ubuntu.com/";
   BUG_REPORT_URL="http://bugs.launchpad.net/ubuntu/";

   zym [root] 31 > cat /proc/mdstat
   Personalities : [linear] [multipath] [raid0] [raid1] [raid6] [raid5]
   [raid4] [raid10]
   md0 : inactive sdi1[7](S) sdg1[11](S) sdh1[6](S) sdf1[12](S)
   sde1[10](S) sdd1[8](S) sdc1[9](S)
          39069229300 blocks super 1.2

   unused devices: <none>

   foreach i ( /dev/sd{c,d,e,f,h,i}1 )
   sudo mdadm --examine $i >> /tmp/examine
   end

   zym [root] 32 > cat /tmp/examine
   /dev/sdc1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 05bb9634:4ecf803a:c519c886:cf3f4867

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : cdf085c0 - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 5
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sdd1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 7e16d55d:3f00c22b:44a750ab:b50a4b5d

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : 2fb6a8f - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 0
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sde1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 7e035b56:d1e1882b:e78a08ad:3ba50667

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : 6bbb74c - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 2
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sdf1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 94251d51:a616e735:e7baccdb:3610013b

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : e9aab94 - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 1
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sdg1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : ad285b4d:222eea5e:0baad052:02eeb7d2

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : 429690b8 - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 3
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sdh1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x13
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 11720780943 (5588.90 GiB 6001.04 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
   Recovery Offset : 1192713176 sectors
              State : clean
        Device UUID : 0ddd2a83:872da375:c7cb7a93:c5bd2ea1

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : e55791e1 - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 4
       Array State : AAAA?A ('A' == active, '.' == missing)

   /dev/sdi1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x1
         Array UUID : 0e9f76b5:4a89171a:a930bccd:78749144
               Name : zym:0  (local to host zym)
      Creation Time : Mon Apr 22 00:08:12 2013
         Raid Level : raid6
       Raid Devices : 6

     Avail Dev Size : 7813772943 (3725.90 GiB 4000.65 GB)
         Array Size : 15627545856 (14903.59 GiB 16002.61 GB)
      Used Dev Size : 7813772928 (3725.90 GiB 4000.65 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 6c35eb93:149c874e:48f7572b:fc6161cc

   Internal Bitmap : 8 sectors from superblock
        Update Time : Thu Jun  8 19:11:59 2017
           Checksum : 6214969b - correct
             Events : 290068

             Layout : left-symmetric
         Chunk Size : 64K

       Device Role : Active device 4
       Array State : AAAA?A ('A' == active, '.' == missing)
   zym [root] 33 >

   ***smartctl output omitted as all disks are healthy with no errors***

Thanks in advance for your help.

Ramesh

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