Dear Bastian,

thanks for picking up on this. We've done some more research, and we now
believe the issue to be upstream, so we've opened a bug report directly with
lvm: https://github.com/lvmteam/lvm2/issues/104
If you check the lvm debug log we posted there, you'll see that it correctly
picks up the filter, finds and scans the right device (sda3), but then rejects
it since at the time of scanning,
/dev/disk/by-path/pci-0000:04:00.0-sas-phy0-lun-0-part3 (the one in the
filter) doesn't exist. This might be a race condition, since on some reboots
it sees part1 and part2, on some only part1, but never part3.
I could also reproduce the problem in Arch (Fedora, surprisingly, has too old
of an LVM version).

to your questions:

> >    - manually activating the root VG in busybox allows us to boot
> >      (by copy/pasting the IMPORT{program} lines from the udev rule)
> 
> Which one?  "pvscan"?  That one does not activate anything.
correct, but I don't think that's relevant any longer.

> >    - replacing /usr/sbin/lvm and /lib/udev/rules.d/69-lvm.rules on
> >      bookworm with the bullseye versions fixes the problem
> 
> What are you replacing exactly?  The bullseye version did not include
> /lib/udev/rules.d/69-lvm.rules at all, see
> https://packages.debian.org/bullseye/amd64/lvm2/filelist.
correct, I used bullseye's 69-lvm-metad.rules and renamed it to 69-lvm.rules
on bookworm.

> Please provide the output of "pvs", "vgs", "lvs" and the kernel log.
again, I don't think it's relevant, but to help understand the situation
better:

  PV                                                      VG               Fmt
Attr PSize  PFree 
  /dev/disk/by-path/pci-0000:04:00.0-sas-phy0-lun-0-part3 test-bookworm-vg
lvm2 a--  <2.73t <2.45t

  VG               #PV #LV #SN Attr   VSize  VFree 
  test-bookworm-vg   1  10   4 wz--n- <2.73t <2.45t

  LV        VG               Attr       LSize   Pool Origin Data%  Meta%  Move
Log Cpy%Sync Convert
  home      test-bookworm-vg owi-aos---  10.00g                                 
                   
  root      test-bookworm-vg owi-aos---  23.28g                                 
                   
  swap_1    test-bookworm-vg -wi-ao---- 976.00m                                 
                   
  var       test-bookworm-vg owi-aos---   9.31g                                 
                   

and 

pci-0000:04:00.0-sas-phy0-lun-0 -> ../../sda
pci-0000:04:00.0-sas-phy0-lun-0-part1 -> ../../sda1
pci-0000:04:00.0-sas-phy0-lun-0-part2 -> ../../sda2
pci-0000:04:00.0-sas-phy0-lun-0-part3 -> ../../sda3

Device       Start        End    Sectors  Size Type
/dev/sda1     2048       4095       2048    1M BIOS boot
/dev/sda2     4096    1003519     999424  488M Linux filesystem
/dev/sda3  1003520 5860532223 5859528704  2.7T Linux LVM


thanks and kind regards,
-Christian



-- 
Dr. Christian Herzog <[email protected]>  support: +41 44 633 26 68
Head, IT Services Group, HPT H 8              voice: +41 44 633 39 50
Department of Physics, ETH Zurich           
8093 Zurich, Switzerland                     http://isg.phys.ethz.ch/

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