Reduce "No runner matching the specified labels was found" errors while runner replacement (#392)

We occasionally encountered those errors while the underlying RunnerReplicaSet is being recreated/replaced on RunnerDeployment.Spec.Template update. It turned out to be due to that the RunnerDeployment controller was waiting for the runner pod becomes `Running`, intead of the new replacement runner to have registered to GitHub. This fixes that, by trying to Runner.Status.Phase to `Running` only after the runner in the runner pod appears to be registered.

A side-effect of this change is that runner controller would call more "ListRunners" GitHub Actions API. I've reviewed and improved the runner controller code and Runner CRD to make make the number of calls minimum. In most cases, ListRunners should be called only twice for each runner creation.

api/v1alpha1/runner_types.go

@@ -125,6 +125,9 @@ type RunnerStatus struct {
 	Phase        string                   `json:"phase"`
 	Reason       string                   `json:"reason"`
 	Message      string                   `json:"message"`
+
+	//+optional
+	LastRegistrationCheckTime *metav1.Time `json:"lastRegistrationCheckTime"`
 }
 
 // RunnerStatusRegistration contains runner registration status

api/v1alpha1/zz_generated.deepcopy.go

@@ -715,6 +715,10 @@ func (in *RunnerSpec) DeepCopy() *RunnerSpec {
 func (in *RunnerStatus) DeepCopyInto(out *RunnerStatus) {
 	*out = *in
 	in.Registration.DeepCopyInto(&out.Registration)
+	if in.LastRegistrationCheckTime != nil {
+		in, out := &in.LastRegistrationCheckTime, &out.LastRegistrationCheckTime
+		*out = (*in).DeepCopy()
+	}
 }
 
 // DeepCopy is an autogenerated deepcopy function, copying the receiver, creating a new RunnerStatus.

charts/actions-runner-controller/Chart.yaml

@@ -15,7 +15,7 @@ type: application
 # This is the chart version. This version number should be incremented each time you make changes
 # to the chart and its templates, including the app version.
 # Versions are expected to follow Semantic Versioning (https://semver.org/)
-version: 0.9.0
+version: 0.10.0
 
 home: https://github.com/summerwind/actions-runner-controller
 

charts/actions-runner-controller/crds/actions.summerwind.dev_runners.yaml

@@ -1541,6 +1541,9 @@ spec:
         status:
           description: RunnerStatus defines the observed state of Runner
           properties:
+            lastRegistrationCheckTime:
+              format: date-time
+              type: string
             message:
               type: string
             phase:

config/crd/bases/actions.summerwind.dev_runners.yaml

@@ -1541,6 +1541,9 @@ spec:
         status:
           description: RunnerStatus defines the observed state of Runner
           properties:
+            lastRegistrationCheckTime:
+              format: date-time
+              type: string
             message:
               type: string
             phase:

controllers/autoscaling.go

@@ -71,7 +71,13 @@ func (r *HorizontalRunnerAutoscalerReconciler) determineDesiredReplicas(rd v1alp
 	}
 
 	metrics := hra.Spec.Metrics
-	if len(metrics) == 0 || metrics[0].Type == v1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns {
+	if len(metrics) == 0 {
+		if len(hra.Spec.ScaleUpTriggers) == 0 {
+			return r.calculateReplicasByQueuedAndInProgressWorkflowRuns(rd, hra)
+		}
+
+		return hra.Spec.MinReplicas, nil
+	} else if metrics[0].Type == v1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns {
 		return r.calculateReplicasByQueuedAndInProgressWorkflowRuns(rd, hra)
 	} else if metrics[0].Type == v1alpha1.AutoscalingMetricTypePercentageRunnersBusy {
 		return r.calculateReplicasByPercentageRunnersBusy(rd, hra)

controllers/integration_test.go

@@ -322,7 +322,11 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 						MinReplicas:                       intPtr(1),
 						MaxReplicas:                       intPtr(3),
 						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
-						Metrics:                           nil,
+						Metrics: []actionsv1alpha1.MetricSpec{
+							{
+								Type: actionsv1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns,
+							},
+						},
 						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
 							{
 								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
@@ -447,7 +451,11 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 						MinReplicas:                       intPtr(1),
 						MaxReplicas:                       intPtr(5),
 						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
-						Metrics:                           nil,
+						Metrics: []actionsv1alpha1.MetricSpec{
+							{
+								Type: actionsv1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns,
+							},
+						},
 						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
 							{
 								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
@@ -493,6 +501,110 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 			env.ExpectRegisteredNumberCountEventuallyEquals(5, "count of fake list runners")
 		})
 
+		It("should create and scale organization's repository runners only on check_run event", func() {
+			name := "example-runnerdeploy"
+
+			{
+				rd := &actionsv1alpha1.RunnerDeployment{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.RunnerDeploymentSpec{
+						Replicas: intPtr(1),
+						Selector: &metav1.LabelSelector{
+							MatchLabels: map[string]string{
+								"foo": "bar",
+							},
+						},
+						Template: actionsv1alpha1.RunnerTemplate{
+							ObjectMeta: metav1.ObjectMeta{
+								Labels: map[string]string{
+									"foo": "bar",
+								},
+							},
+							Spec: actionsv1alpha1.RunnerSpec{
+								Repository: "test/valid",
+								Image:      "bar",
+								Group:      "baz",
+								Env: []corev1.EnvVar{
+									{Name: "FOO", Value: "FOOVALUE"},
+								},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, rd, "test RunnerDeployment")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(1, "count of fake list runners")
+			}
+
+			// Scale-up to 3 replicas by the default TotalNumberOfQueuedAndInProgressWorkflowRuns-based scaling
+			// See workflowRunsFor3Replicas_queued and workflowRunsFor3Replicas_in_progress for GitHub List-Runners API responses
+			// used while testing.
+			{
+				hra := &actionsv1alpha1.HorizontalRunnerAutoscaler{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.HorizontalRunnerAutoscalerSpec{
+						ScaleTargetRef: actionsv1alpha1.ScaleTargetRef{
+							Name: name,
+						},
+						MinReplicas:                       intPtr(1),
+						MaxReplicas:                       intPtr(5),
+						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
+						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
+							{
+								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
+									CheckRun: &actionsv1alpha1.CheckRunSpec{
+										Types:  []string{"created"},
+										Status: "pending",
+									},
+								},
+								Amount:   1,
+								Duration: metav1.Duration{Duration: time.Minute},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, hra, "test HorizontalRunnerAutoscaler")
+
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(1, "count of fake list runners")
+			}
+
+			// Scale-up to 2 replicas on first check_run create webhook event
+			{
+				env.SendOrgCheckRunEvent("test", "valid", "pending", "created")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1, "runner sets after webhook")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 2, "runners after first webhook event")
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(2, "count of fake list runners")
+			}
+
+			// Scale-up to 3 replicas on second check_run create webhook event
+			{
+				env.SendOrgCheckRunEvent("test", "valid", "pending", "created")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 3, "runners after second webhook event")
+			}
+
+			env.ExpectRegisteredNumberCountEventuallyEquals(3, "count of fake list runners")
+		})
+
 		It("should create and scale user's repository runners on pull_request event", func() {
 			name := "example-runnerdeploy"
 
@@ -554,7 +666,11 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 						MinReplicas:                       intPtr(1),
 						MaxReplicas:                       intPtr(3),
 						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
-						Metrics:                           nil,
+						Metrics: []actionsv1alpha1.MetricSpec{
+							{
+								Type: actionsv1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns,
+							},
+						},
 						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
 							{
 								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
@@ -622,6 +738,99 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 			}
 		})
 
+		It("should create and scale user's repository runners only on pull_request event", func() {
+			name := "example-runnerdeploy"
+
+			{
+				rd := &actionsv1alpha1.RunnerDeployment{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.RunnerDeploymentSpec{
+						Replicas: intPtr(1),
+						Selector: &metav1.LabelSelector{
+							MatchLabels: map[string]string{
+								"foo": "bar",
+							},
+						},
+						Template: actionsv1alpha1.RunnerTemplate{
+							ObjectMeta: metav1.ObjectMeta{
+								Labels: map[string]string{
+									"foo": "bar",
+								},
+							},
+							Spec: actionsv1alpha1.RunnerSpec{
+								Repository: "test/valid",
+								Image:      "bar",
+								Group:      "baz",
+								Env: []corev1.EnvVar{
+									{Name: "FOO", Value: "FOOVALUE"},
+								},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, rd, "test RunnerDeployment")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				hra := &actionsv1alpha1.HorizontalRunnerAutoscaler{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.HorizontalRunnerAutoscalerSpec{
+						ScaleTargetRef: actionsv1alpha1.ScaleTargetRef{
+							Name: name,
+						},
+						MinReplicas:                       intPtr(1),
+						MaxReplicas:                       intPtr(3),
+						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
+						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
+							{
+								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
+									PullRequest: &actionsv1alpha1.PullRequestSpec{
+										Types:    []string{"created"},
+										Branches: []string{"main"},
+									},
+								},
+								Amount:   1,
+								Duration: metav1.Duration{Duration: time.Minute},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, hra, "test HorizontalRunnerAutoscaler")
+
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(1, "count of fake runners after HRA creation")
+			}
+
+			// Scale-up to 2 replicas on first pull_request create webhook event
+			{
+				env.SendUserPullRequestEvent("test", "valid", "main", "created")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1, "runner sets after webhook")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 2, "runners after first webhook event")
+				ExpectHRADesiredReplicasEquals(ctx, ns.Name, name, 2, "runner deployment desired replicas")
+			}
+
+			// Scale-up to 3 replicas on second pull_request create webhook event
+			{
+				env.SendUserPullRequestEvent("test", "valid", "main", "created")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 3, "runners after second webhook event")
+				ExpectHRADesiredReplicasEquals(ctx, ns.Name, name, 3, "runner deployment desired replicas")
+			}
+		})
+
 		It("should create and scale user's repository runners on check_run event", func() {
 			name := "example-runnerdeploy"
 
@@ -681,7 +890,11 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 						MinReplicas:                       intPtr(1),
 						MaxReplicas:                       intPtr(5),
 						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
-						Metrics:                           nil,
+						Metrics: []actionsv1alpha1.MetricSpec{
+							{
+								Type: actionsv1alpha1.AutoscalingMetricTypeTotalNumberOfQueuedAndInProgressWorkflowRuns,
+							},
+						},
 						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
 							{
 								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
@@ -727,6 +940,110 @@ var _ = Context("INTEGRATION: Inside of a new namespace", func() {
 			env.ExpectRegisteredNumberCountEventuallyEquals(5, "count of fake list runners")
 		})
 
+		It("should create and scale user's repository runners only on check_run event", func() {
+			name := "example-runnerdeploy"
+
+			{
+				rd := &actionsv1alpha1.RunnerDeployment{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.RunnerDeploymentSpec{
+						Replicas: intPtr(1),
+						Selector: &metav1.LabelSelector{
+							MatchLabels: map[string]string{
+								"foo": "bar",
+							},
+						},
+						Template: actionsv1alpha1.RunnerTemplate{
+							ObjectMeta: metav1.ObjectMeta{
+								Labels: map[string]string{
+									"foo": "bar",
+								},
+							},
+							Spec: actionsv1alpha1.RunnerSpec{
+								Repository: "test/valid",
+								Image:      "bar",
+								Group:      "baz",
+								Env: []corev1.EnvVar{
+									{Name: "FOO", Value: "FOOVALUE"},
+								},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, rd, "test RunnerDeployment")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(1, "count of fake list runners")
+			}
+
+			// Scale-up to 3 replicas by the default TotalNumberOfQueuedAndInProgressWorkflowRuns-based scaling
+			// See workflowRunsFor3Replicas_queued and workflowRunsFor3Replicas_in_progress for GitHub List-Runners API responses
+			// used while testing.
+			{
+				hra := &actionsv1alpha1.HorizontalRunnerAutoscaler{
+					ObjectMeta: metav1.ObjectMeta{
+						Name:      name,
+						Namespace: ns.Name,
+					},
+					Spec: actionsv1alpha1.HorizontalRunnerAutoscalerSpec{
+						ScaleTargetRef: actionsv1alpha1.ScaleTargetRef{
+							Name: name,
+						},
+						MinReplicas:                       intPtr(1),
+						MaxReplicas:                       intPtr(5),
+						ScaleDownDelaySecondsAfterScaleUp: intPtr(1),
+						ScaleUpTriggers: []actionsv1alpha1.ScaleUpTrigger{
+							{
+								GitHubEvent: &actionsv1alpha1.GitHubEventScaleUpTriggerSpec{
+									CheckRun: &actionsv1alpha1.CheckRunSpec{
+										Types:  []string{"created"},
+										Status: "pending",
+									},
+								},
+								Amount:   1,
+								Duration: metav1.Duration{Duration: time.Minute},
+							},
+						},
+					},
+				}
+
+				ExpectCreate(ctx, hra, "test HorizontalRunnerAutoscaler")
+
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1)
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 1)
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(1, "count of fake list runners")
+			}
+
+			// Scale-up to 2 replicas on first check_run create webhook event
+			{
+				env.SendUserCheckRunEvent("test", "valid", "pending", "created")
+				ExpectRunnerSetsCountEventuallyEquals(ctx, ns.Name, 1, "runner sets after webhook")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 2, "runners after first webhook event")
+			}
+
+			{
+				env.ExpectRegisteredNumberCountEventuallyEquals(2, "count of fake list runners")
+			}
+
+			// Scale-up to 3 replicas on second check_run create webhook event
+			{
+				env.SendUserCheckRunEvent("test", "valid", "pending", "created")
+				ExpectRunnerSetsManagedReplicasCountEventuallyEquals(ctx, ns.Name, 3, "runners after second webhook event")
+			}
+
+			env.ExpectRegisteredNumberCountEventuallyEquals(3, "count of fake list runners")
+		})
+
 	})
 })
 

controllers/runner_controller.go

@@ -22,6 +22,7 @@ import (
 	"fmt"
 	gogithub "github.com/google/go-github/v33/github"
 	"github.com/summerwind/actions-runner-controller/hash"
+	"k8s.io/apimachinery/pkg/util/wait"
 	"strings"
 	"time"
 
@@ -129,8 +130,8 @@ func (r *RunnerReconciler) Reconcile(req ctrl.Request) (ctrl.Result, error) {
 			newRunner := runner.DeepCopy()
 			newRunner.ObjectMeta.Finalizers = finalizers
 
-			if err := r.Update(ctx, newRunner); err != nil {
-				log.Error(err, "Failed to update runner")
+			if err := r.Patch(ctx, newRunner, client.MergeFrom(&runner)); err != nil {
+				log.Error(err, "Failed to update runner for finalizer removal")
 				return ctrl.Result{}, err
 			}
 
@@ -159,31 +160,23 @@ func (r *RunnerReconciler) Reconcile(req ctrl.Request) (ctrl.Result, error) {
 		}
 
 		if err := r.Create(ctx, &newPod); err != nil {
+			if kerrors.IsAlreadyExists(err) {
+				// Gracefully handle pod-already-exists errors due to informer cache delay.
+				// Without this we got a few errors like the below on new runner pod:
+				// 2021-03-16T00:23:10.116Z        ERROR   controller-runtime.controller   Reconciler error      {"controller": "runner-controller", "request": "default/example-runnerdeploy-b2g2g-j4mcp", "error": "pods \"example-runnerdeploy-b2g2g-j4mcp\" already exists"}
+				log.Info("Runner pod already exists. Probably this pod has been already created in previous reconcilation but the new pod is not yet cached.")
+
+				return ctrl.Result{RequeueAfter: 10 * time.Second}, nil
+			}
+
 			log.Error(err, "Failed to create pod resource")
+
 			return ctrl.Result{}, err
 		}
 
 		r.Recorder.Event(&runner, corev1.EventTypeNormal, "PodCreated", fmt.Sprintf("Created pod '%s'", newPod.Name))
 		log.Info("Created runner pod", "repository", runner.Spec.Repository)
 	} else {
-		// If pod has ended up succeeded we need to restart it
-		// Happens e.g. when dind is in runner and run completes
-		restart := pod.Status.Phase == corev1.PodSucceeded
-
-		if !restart && runner.Status.Phase != string(pod.Status.Phase) {
-			updated := runner.DeepCopy()
-			updated.Status.Phase = string(pod.Status.Phase)
-			updated.Status.Reason = pod.Status.Reason
-			updated.Status.Message = pod.Status.Message
-
-			if err := r.Status().Update(ctx, updated); err != nil {
-				log.Error(err, "Failed to update runner status")
-				return ctrl.Result{}, err
-			}
-
-			return ctrl.Result{}, nil
-		}
-
 		if !pod.ObjectMeta.DeletionTimestamp.IsZero() {
 			deletionTimeout := 1 * time.Minute
 			currentTime := time.Now()
@@ -220,6 +213,10 @@ func (r *RunnerReconciler) Reconcile(req ctrl.Request) (ctrl.Result, error) {
 			}
 		}
 
+		// If pod has ended up succeeded we need to restart it
+		// Happens e.g. when dind is in runner and run completes
+		restart := pod.Status.Phase == corev1.PodSucceeded
+
 		if pod.Status.Phase == corev1.PodRunning {
 			for _, status := range pod.Status.ContainerStatuses {
 				if status.Name != containerName {
@@ -244,24 +241,45 @@ func (r *RunnerReconciler) Reconcile(req ctrl.Request) (ctrl.Result, error) {
 			return ctrl.Result{}, err
 		}
 
+		var registrationRecheckDelay time.Duration
+
 		// all checks done below only decide whether a restart is needed
 		// if a restart was already decided before, there is no need for the checks
-		// saving API calls and scary log messages
+		// saving API calls and scary{ log messages
 		if !restart {
+			registrationCheckInterval := time.Minute
 
-			notRegistered := false
+			// We want to call ListRunners GitHub Actions API only once per runner per minute.
+			// This if block, in conjunction with:
+			//   return ctrl.Result{RequeueAfter: registrationRecheckDelay}, nil
+			// achieves that.
+			if lastCheckTime := runner.Status.LastRegistrationCheckTime; lastCheckTime != nil {
+				nextCheckTime := lastCheckTime.Add(registrationCheckInterval)
+				if nextCheckTime.After(time.Now()) {
+					log.Info(
+						fmt.Sprintf("Skipping registration check because it's deferred until %s", nextCheckTime),
+					)
+
+					// Note that we don't need to explicitly requeue on this reconcilation because
+					// the requeue should have been already scheduled previsouly
+					// (with `return ctrl.Result{RequeueAfter: registrationRecheckDelay}, nil` as noted above and coded below)
+					return ctrl.Result{}, nil
+				}
+			}
+
+			notFound := false
 			offline := false
 
 			runnerBusy, err := r.GitHubClient.IsRunnerBusy(ctx, runner.Spec.Enterprise, runner.Spec.Organization, runner.Spec.Repository, runner.Name)
+
+			currentTime := time.Now()
+
 			if err != nil {
 				var notFoundException *github.RunnerNotFound
 				var offlineException *github.RunnerOffline
 				if errors.As(err, &notFoundException) {
-					log.V(1).Info("Failed to check if runner is busy. Either this runner has never been successfully registered to GitHub or it still needs more time.", "runnerName", runner.Name)
-
-					notRegistered = true
+					notFound = true
 				} else if errors.As(err, &offlineException) {
-					log.V(1).Info("GitHub runner appears to be offline, waiting for runner to get online ...", "runnerName", runner.Name)
 					offline = true
 				} else {
 					var e *gogithub.RateLimitError
@@ -293,40 +311,91 @@ func (r *RunnerReconciler) Reconcile(req ctrl.Request) (ctrl.Result, error) {
 			}
 
 			registrationTimeout := 10 * time.Minute
-			currentTime := time.Now()
-			registrationDidTimeout := currentTime.Sub(pod.CreationTimestamp.Add(registrationTimeout)) > 0
+			durationAfterRegistrationTimeout := currentTime.Sub(pod.CreationTimestamp.Add(registrationTimeout))
+			registrationDidTimeout := durationAfterRegistrationTimeout > 0
 
-			if notRegistered && registrationDidTimeout {
-				log.Info(
-					"Runner failed to register itself to GitHub in timely manner. "+
-						"Recreating the pod to see if it resolves the issue. "+
-						"CAUTION: If you see this a lot, you should investigate the root cause. "+
-						"See https://github.com/summerwind/actions-runner-controller/issues/288",
-					"podCreationTimestamp", pod.CreationTimestamp,
-					"currentTime", currentTime,
-					"configuredRegistrationTimeout", registrationTimeout,
-				)
+			if notFound {
+				if registrationDidTimeout {
+					log.Info(
+						"Runner failed to register itself to GitHub in timely manner. "+
+							"Recreating the pod to see if it resolves the issue. "+
+							"CAUTION: If you see this a lot, you should investigate the root cause. "+
+							"See https://github.com/summerwind/actions-runner-controller/issues/288",
+						"podCreationTimestamp", pod.CreationTimestamp,
+						"currentTime", currentTime,
+						"configuredRegistrationTimeout", registrationTimeout,
+					)
 
-				restart = true
+					restart = true
+				} else {
+					log.V(1).Info(
+						"Runner pod exists but we failed to check if runner is busy. Apparently it still needs more time.",
+						"runnerName", runner.Name,
+					)
+				}
+			} else if offline {
+				if registrationDidTimeout {
+					log.Info(
+						"Already existing GitHub runner still appears offline . "+
+							"Recreating the pod to see if it resolves the issue. "+
+							"CAUTION: If you see this a lot, you should investigate the root cause. ",
+						"podCreationTimestamp", pod.CreationTimestamp,
+						"currentTime", currentTime,
+						"configuredRegistrationTimeout", registrationTimeout,
+					)
+
+					restart = true
+				} else {
+					log.V(1).Info(
+						"Runner pod exists but the GitHub runner appears to be still offline. Waiting for runner to get online ...",
+						"runnerName", runner.Name,
+					)
+				}
 			}
 
-			if offline && registrationDidTimeout {
-				log.Info(
-					"Already existing GitHub runner still appears offline . "+
-						"Recreating the pod to see if it resolves the issue. "+
-						"CAUTION: If you see this a lot, you should investigate the root cause. ",
-					"podCreationTimestamp", pod.CreationTimestamp,
-					"currentTime", currentTime,
-					"configuredRegistrationTimeout", registrationTimeout,
-				)
-
-				restart = true
+			if (notFound || offline) && !registrationDidTimeout {
+				registrationRecheckDelay = registrationCheckInterval + wait.Jitter(10*time.Second, 0.1)
 			}
-
 		}
 
 		// Don't do anything if there's no need to restart the runner
 		if !restart {
+			// This guard enables us to update runner.Status.Phase to `Running` only after
+			// the runner is registered to GitHub.
+			if registrationRecheckDelay > 0 {
+				log.V(1).Info(fmt.Sprintf("Rechecking the runner registration in %s", registrationRecheckDelay))
+
+				updated := runner.DeepCopy()
+				updated.Status.LastRegistrationCheckTime = &metav1.Time{Time: time.Now()}
+
+				if err := r.Status().Patch(ctx, updated, client.MergeFrom(&runner)); err != nil {
+					log.Error(err, "Failed to update runner status")
+					return ctrl.Result{}, err
+				}
+
+				return ctrl.Result{RequeueAfter: registrationRecheckDelay}, nil
+			}
+
+			if runner.Status.Phase != string(pod.Status.Phase) {
+				if pod.Status.Phase == corev1.PodRunning {
+					// Seeing this message, you can expect the runner to become `Running` soon.
+					log.Info(
+						"Runner appears to have registered and running.",
+						"podCreationTimestamp", pod.CreationTimestamp,
+					)
+				}
+
+				updated := runner.DeepCopy()
+				updated.Status.Phase = string(pod.Status.Phase)
+				updated.Status.Reason = pod.Status.Reason
+				updated.Status.Message = pod.Status.Message
+
+				if err := r.Status().Patch(ctx, updated, client.MergeFrom(&runner)); err != nil {
+					log.Error(err, "Failed to update runner status")
+					return ctrl.Result{}, err
+				}
+			}
+
 			return ctrl.Result{}, nil
 		}
 

controllers/runnerdeployment_controller.go

@@ -194,7 +194,10 @@ func (r *RunnerDeploymentReconciler) Reconcile(req ctrl.Request) (ctrl.Result, e
 				Namespace: newestSet.Namespace,
 				Name:      newestSet.Name,
 			}).
-				Info("Waiting until the newest runner replica set to be 100% available")
+				Info("Waiting until the newest runner replica set to be 100% available",
+					"ready", readyReplicas,
+					"desired", currentDesiredReplicas,
+				)
 
 			return ctrl.Result{RequeueAfter: 10 * time.Second}, nil
 		}

github/github.go

@@ -158,7 +158,7 @@ func (c *Client) ListRunners(ctx context.Context, enterprise, org, repo string)
 
 	var runners []*github.Runner
 
-	opts := github.ListOptions{PerPage: 10}
+	opts := github.ListOptions{PerPage: 100}
 	for {
 		list, res, err := c.listRunners(ctx, enterprise, owner, repo, &opts)