My advice is to backup the $PGDATA tree (which you said was in progress), then pg_resetxlog, then cross-check the hell out of the data you see. Only if you can detect some data problems can we guess at something else to do ...
OK. I plan to gather the usual suspects and try to get an accurate picture of the chain of events first thing tomorrow. Then we'll likely proceed as you suggest.
Thinking about your comments and reading xlog.c, it almost seems as though the mount points were momentarily reversed between /replica and /production. I.e. that the /production mount point was used near the beginning of StartupXLOG() for ReadControlFile(), and the /replica mount point was used at the end of StartupXLOG() for UpdateControlFile(). But I have no idea how that could happen.
Thanks,
Joe
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