5. We easily reach 1024 webserver processes, apache 1.3.
This really sounds like a lot more httpd mod_perl processes than you should need, even on a heavily loaded system. Are you using a light frontend proxy/accelerator?
http://perl.apache.org/docs/1.0/guide/strategy.html
If not, you definitely should be as that will deal with all the slow clients out there much better than chewing up your valuable mod_perl enabled httpd procs and database connections.
Rob
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