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test: wait for bootstrap before the operator upgrade - #40541

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ggevay:gabor/orchestratord-upgrade-wait-for-bootstrap
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MaterializeInc:mainfrom
ggevay:gabor/orchestratord-upgrade-wait-for-bootstrap

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@ggevay ggevay commented Nov 6, 2026 •

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Motivation

Orchestratord operator upgrade fails with Never completed when the upgrade starts while the first generation is still bootstrapping (18651, 18690). The operator reports a rollout complete before coordinator bootstrap, and this workflow only checked pods before upgrading. The read-only generation then initializes shards the old one hasn't created yet, the old one halts on their newer version tag and crash-loops, and the new one never gets ready.

This stops the test from starting that race. The product side is SQL-885.

Description

Before each upgrade from a fresh environment, the workflow now waits for environmentd to answer SQL, which it does only after bootstrap.

Verification

This job runs only in Nightly. In kind on the v26.50.0-rc.1 images, I stopped the first generation's environmentd with SIGSTOP as soon as the operator reported it complete, and resumed it 60 s later:

  • Without this change: the test upgraded during the freeze, the operator after 2 s and the new generation after 13 s. After the resume, the old generation restarted 6 times and the rollout had not completed after 8 minutes.
  • With this change: the test held for the whole freeze, upgraded 7 s after the resume, and the rollout completed.

Both runs stopped after the first upgrade. The full job, including the second wait, passed without a freeze in Nightly 18692.

🤖 Generated with Claude Code

The operator reports a rollout complete before coordinator bootstrap, so
the workflow could upgrade while the first generation was still
bootstrapping. Wait until environmentd answers SQL first.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
@ggevay
ggevay marked this pull request as ready for review November 6, 2026 16:02
@ggevay
ggevay requested a review from a team November 6, 2026 16:02

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