Hi,

I too have been experiencing this with a busy PostgreSQL instance.

I have been following the updates to the 9.4 branch hoping a fix will appear, 
but sadly no luck yet. I have manually replicated the issue on 9.4.4, 9.4.10 
and 9.4.12. My replication steps are:

BEGIN;
CREATE TABLE x (id BIGSERIAL PRIMARY KEY, payload1 VARCHAR, payload2 VARCHAR, 
payload3 VARCHAR, payload4 BIGINT, payload5 BIGINT);
/* Repeat until 2,000,000 rows are inserted */
INSERT INTO x (id, payload1, payload2, payload3, payload4, payload5) VALUES 
(random values of varying length/size to force random toast usage);
COMMIT;

VACUUM (ANALYZE, FULL);

BEGIN;
/* Repeat until all 2,000,000 rows are updated */
UPDATE x SET payload1 = , payload2 = , payload3 = , payload4 = , payload5 = ... 
again random values of varying length/size to force random toast usage
COMMIT;

VACCUM (ANALYZE, FULL);

The second vacuum causes an ERROR identical to that you are reporting below 
(unexpected chunk number n (expected n) for toast value...). However it may 
take up to ten attempts to replicate it.

Out of interest, are you using any tablespaces other than pg_default? I can 
only replicate the issue when using separately mounted tablespaces.

I have been investigating this quite extensively and everything I can find on 
the web suggests data corruption. However running the the following DO reports 
no errors and I can dump the database without issue.

DO $$
DECLARE

        curid INT := 0;
        vcontent RECORD;
        badid BIGINT;
    
        var1_sub VARCHAR;
        var2_sub VARCHAR;
        var3_sub VARCHAR;
        var4_sub VARCHAR;
        var5_sub VARCHAR;
        
BEGIN
        FOR badid IN SELECT id FROM x 
        LOOP
            curid = curid + 1;
                
            IF curid % 100000 = 0 
            THEN
                RAISE NOTICE '% rows inspected', curid;
            END IF;
            
            BEGIN
                SELECT *
                INTO vcontent
                FROM x
                WHERE rowid = badid;
            
                var1_sub := SUBSTR(vcontent.var1,2000,5000);
                var2_sub := SUBSTR(vcontent.var2,2000,5000);   
                var3_sub := SUBSTR(vcontent.var3,2000,5000);
                var4_sub := SUBSTR(vcontent.var4::VARCHAR,2000,5000);
                var5_sub := SUBSTR(vcontent.var5::VARCHAR,2000,5000);
            
            EXCEPTION WHEN OTHERS THEN
                RAISE NOTICE 'Data for rowid % is corrupt', badid;
                CONTINUE;
                END;
        
        END LOOP;
END;
$$;

I also found the following has been reported: 
https://www.postgresql.org/message-id/20161201165505.4360.28...@wrigleys.postgresql.org

Best wishes,
Harry

> On 7 Jun 2017, at 15:22, Achilleas Mantzios <ach...@matrix.gatewaynet.com> 
> wrote:
> 
> On 07/06/2017 16:33, ADSJ (Adam Sjøgren) wrote:
>> Our database has started reporting errors like this:
>> 
>>   2017-05-31 13:48:10 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 14242189 in pg_toast_10919630
>>       ...
>>   2017-06-01 11:06:56 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 19573520 in pg_toast_10919630
>> 
>> (157 times, for different toast values, same pg_toast_nnn). pg_toast_10919630
>> corresponds to a table with around 168 million rows.
>> 
>> These went away, but the next day we got similar errors from another
>> table:
>> 
>>   2017-06-02 05:59:50 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 47060150 in pg_toast_10920100
>>       ...
>>   2017-06-02 06:14:54 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 47226455 in pg_toast_10920100
>> 
>> (Only 4 this time) pg_toast_10920100 corresponds to a table with holds
>> around 320 million rows (these are our two large tables).
>> 
>> The next day we got 6 such errors and the day after 10 such errors. On
>> June 5th we got 94, yesterday we got 111, of which one looked a little
>> different:
>> 
>>   2017-06-06 17:32:21 CEST ERROR:  unexpected chunk size 1996 (expected 
>> 1585) in final chunk 0 for toast value 114925100 in pg_toast_10920100
>> 
>> and today the logs have 65 lines, ending with these:
>> 
>>   2017-06-07 14:49:53 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 131114834 in pg_toast_10920100
>>   2017-06-07 14:53:41 CEST ERROR:  unexpected chunk number 0 (expected 1) 
>> for toast value 131149566 in pg_toast_10920100
> First try to find which tables those toast relations refer to :
> select 10919630::regclass , 10920100::regclass ;
> Are those critical tables? Can you restore them somehow?
> 
> Also you may consider
> REINDEX TABLE pg_toast.pg_toast_10920100;
> REINDEX TABLE pg_toast.pg_toast_10919630;
> REINDEX TABLE <name of table 10920100>;
> REINDEX TABLE <name of table 10919630>;
> 
> also VACUUM the above tables.
> 
> You might want to write a function which iterates over the damaged table's 
> rows in order to identify the damaged row(s). And then do some good update to 
> create a new version.
> 
>> The database is 10 TB on disk (SSDs) and runs on a 48 core server with 3
>> TB RAM on Ubuntu 14.04 (Linux 3.18.13).
>> 
>> We are updating rows in the database a lot/continuously.
>> 
>> There are no apparent indications of hardware errors (like ECC) in
>> dmesg, nor any error messages logged by the LSI MegaRAID controller, as
>> far as I can tell.
>> 
>> We are running PostgreSQL 9.3.14 currently.
>> 
>> The only thing I could see in the release notes since 9.3.14 that might
>> be related is this:
>> 
>>  "* Avoid very-low-probability data corruption due to testing tuple
>>     visibility without holding buffer lock (Thomas Munro, Peter Geoghegan,
>>     Tom Lane)"
>> 
>> Although reading more about it, it doesn't sound like it would exhibit
>> the symptoms we see?
>> 
>> We have recently increased the load (to around twice the number of
>> cores), though, which made me think we could be triggering corner cases
>> we haven't hit before.
>> 
>> We will be upgrading to PostgreSQL 9.3.17 during the weekend, but I'd like 
>> to hear
>> if anyone has seen something like this, or have some ideas of how to
>> investigate/what the cause might be.
>> 
>> 
>>   Best regards,
>> 
>>     Adam
>> 
> 
> -- 
> Achilleas Mantzios
> IT DEV Lead
> IT DEPT
> Dynacom Tankers Mgmt
> 
> 
> 
> -- 
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