Hello Mr.Nelson,

This issue is reproducible in 4.1 kernel also.
I found the use case where it is almost every time reproducible.

1. Conider that we have two RFS partition, and current root is 
/dev/mmcblk0p15. Another RFS partition /dev/mmcblk0p16 is not in use.
2. Create RFS tar of 390MB(compressed size. Uncompressed size is 487MB) of 
size. I had include some big files in it. (I had copied 35 files of size 
10MB each).
3. Copy this big tar e.g. rootfs.tar.gz to board.
4. Mount unused partition i.e. /dev/mmcblk0p16 to /mnt/rfs_test.
5. Delete content from /mnt/rfs_test/, using command
rm -rf /mnt/rfs_test/*
6. Untar rootfs.tar.gz to /mnt/rfs_test/
tar -xzvf /home/rootfs.tar.gz -C /mnt/rfs_test/
7. From another ssh terminal run 
while [ true ];do dd if=/dev/mmcblk0p16 of=/dev/null bs=1M; done
8. From yet another terminal observe the syslog, or dmesg
while [ ture ] ; do clear; dmesg | tail -n 30; sleep 2;done
9. Before tar extraction completes you will see error reproduced.

So It doesn't seem to be mmc driver issue, isn't it ?
Do you have any suggestion/pointer for me ?

Thank you,

Regards,
Ankur

On Tuesday, 19 July 2016 22:38:25 UTC+5:30, RobertCNelson wrote:
>
>
>
> On Tue, Jul 19, 2016 at 11:11 AM, Ankur Tank <art...@gmail.com 
> <javascript:>> wrote:
>
>>
>> We are using BeagleBoneBlack based custom Linux board.  
>> It has 256MB of RAM and 4GB of eMMC.   
>> Currently RFS size of the project is 163MB. While RFS partition size is 
>> 500MB.  
>> For testing, we added 20 number of big files(10MB size) and started 
>> firmware upgrade process.  
>>
>> During the firmware Upgrade process we see following error when roofs is 
>> being written,
>>
>> We could solve it by changing 
>> /proc/sys/vm/min_free_kbytes
>>
>> from *2005* to *4096*.
>>
>> *But now my doubt is what should be the ideal value for that, what 
>> factors we should consider while calculating it. From the kernel 
>> documentation I don't get that information, *
>> *but I could understand one thing that is this value can not be too low 
>> or too high or else system will break.*
>>
>> Any suggestion/pointer ?
>>
>>     [ 6676.674219] mmcqd/1: page allocation failure: order:1, mode:
>> 0x200020
>>     [ 6676.674256] CPU: 0 PID: 612 Comm: mmcqd/1 Tainted: P           O 
>> 3.12.10-005-ts-armv7l #2
>>     [ 6676.674321] [<c0012d24>] (unwind_backtrace+0x0/0xf4) from [<
>> c0011130>] (show_stack+0x10/0x14)
>>     [ 6676.674355] [<c0011130>] (show_stack+0x10/0x14) from [<c0087548>] 
>> (warn_alloc_failed+0xe0/0x118)
>>     [ 6676.674383] [<c0087548>] (warn_alloc_failed+0xe0/0x118) from [<
>> c008a3ac>] (__alloc_pages_nodemask+0x74c/0x8f8)
>>     [ 6676.674413] [<c008a3ac>] (__alloc_pages_nodemask+0x74c/0x8f8) from 
>> [<c00b2e8c>] (cache_alloc_refill+0x328/0x620)
>>     [ 6676.674436] [<c00b2e8c>] (cache_alloc_refill+0x328/0x620) from [<
>> c00b3224>] (__kmalloc+0xa0/0xe8)
>>     [ 6676.674471] [<c00b3224>] (__kmalloc+0xa0/0xe8) from [<c0212904>] (
>> edma_prep_slave_sg+0x84/0x388)
>>     [ 6676.674505] [<c0212904>] (edma_prep_slave_sg+0x84/0x388) from [<
>> c02ec0a0>] (omap_hsmmc_request+0x414/0x508)
>>     [ 6676.674544] [<c02ec0a0>] (omap_hsmmc_request+0x414/0x508) from [<
>> c02d6748>] (mmc_start_request+0xc4/0xe0)
>>     [ 6676.674568] [<c02d6748>] (mmc_start_request+0xc4/0xe0) from [<
>> c02d7530>] (mmc_start_req+0x2d8/0x38c)
>>     [ 6676.674589] [<c02d7530>] (mmc_start_req+0x2d8/0x38c) from [<
>> c02e4818>] (mmc_blk_issue_rw_rq+0xb4/0x9d8)
>>     [ 6676.674611] [<c02e4818>] (mmc_blk_issue_rw_rq+0xb4/0x9d8) from [<
>> c02e52e0>] (mmc_blk_issue_rq+0x1a4/0x468)
>>     [ 6676.674631] [<c02e52e0>] (mmc_blk_issue_rq+0x1a4/0x468) from [<
>> c02e5c68>] (mmc_queue_thread+0x88/0x118)
>>     [ 6676.674657] [<c02e5c68>] (mmc_queue_thread+0x88/0x118) from [<
>> c004d8b8>] (kthread+0xb4/0xb8)
>>     [ 6676.674681] [<c004d8b8>] (kthread+0xb4/0xb8) from [<c000e298>] (
>> ret_from_fork+0x14/0x3c)
>>
>
> This actually smells very much like the random mmc issues we saw on 
> "3.8.x" based images... mmc wasn't really fixed/solid till the 3.14.x 
> timeline...  Not sure how much of that was back-ported to 3.12.10...
>
> Regards,
>
> -- 
> Robert Nelson
> https://rcn-ee.com/
>

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