I am the admin of a test lab for server storage software development and for tape library testing. We have a LOT of hard drives. Just the performance department has 108 16 drive trays of FC storage. Over all three labs, I have approximately 600 FC trays. I also have around 400 SAS trays with 3.5" drives and about 150 SAS trays with 2.5" drives. Of the SAS trays, about 2/3 are just trays with SAS RAID controllers in the system, while the other 1/3 have their own RAID controllers or are attached to another tray with its own RAID controller. Many are partially filled, some are completely filled. I also have 90 Dell R910 systems with 13 or 15 2.5" SAS drives. I have configured and maintain every single one of those trays over the last 5 and a half years.
Now, addressing these drives in particular: When my company released a new product 4 years ago, based on the Dell R910 and two MD1220 trays, along with a lot of other storage, Dell took the lowest bidder on the drives we needed, 146GB 15k SAS. The winning bidder happened to be Toshiba, which is still using the Fujitsu name at the time. The specific drive was the mbe2147rc.
Our first systems for testing came in with 13 drives in the node and 17 drives in each MD1220 tray, three months before release to the public. Less than 3 months after release, we started having issues with drives failing. In some cases, they even failed in such a way that it spiked power back through the backplane and killed nearby drives and the backplane. Three months after that, we started getting complaints from our customers on the reliability of these drives. I was having to replace these drives 3-6 at a time on our test systems after less than a year. The reliability was HORRIBLE. We started getting drives with the Toshiba name on them instead of the Fujitsu name, but the same model number. They had the same issue. After the one year point, we told Dell to specifically use the Seagate Saavio series drive because of these reliability problems. We also started using the Seagate drives for all replacements. In the end, we did a full recall on all customer drives to replace them with Seagate drives. It cost us a pretty penny. They did not, however, issue that recall for internal drives, and many drives made it to me to use as spare parts. I got an entire pallet of those drives, 12 in each case and 12 cases, from our service department. I used them all before the three year mark on these drives. I have gone through since then to make sure we don't have any left. I recent received a system from our Irvine office that was loaded with them, and hadn't been turned on for over a year, and they are failing like crazy now. I built it as a VM host with those drives in a RAID 6 set, only to have the set die twice now because of too many failed drives at once.
My estimate of 1200 is probably low ball, and yes, that was every drive that I have had in this lab except for that most recent system. All my 146GB SAS drives are now Seagate Saavios, and I had the first one of those die this past weekend. In that time, 4 years, I've replaced a confirmed 3008 (188 cases of 16 each) Seagate Constellation ES 1TB and 2TB and Barracuda ES 1TB drives from our FC sets, but better than half of those are still in service. Yes, I do go through that many drives, about 1500 per year. My budget reflects that. I also spend about $3000 per year on FC cables and $1000 on cat 6 cables.
There was indeed a 100% failure rate within 3 years of those horrible drives, many taken out by the drives next to them. The failure was always the same, failure of the central bearing, either seizing the drive or leaving it sounding like a pepper grinder when running. Many of the ones that seized were the ones that sent the power spike through the backplane to kill other drives. That mostly happened in the central node, where the drives were stacked in 4s. Either the top or bottom drive would be left running, but due to the system config, running in mirrored pairs, would leave the system unable to run and had to have the software rebuilt.
Our newest lines use Seagate Saavio 2.5" and HGST 3.5" drives for the best in reliability, trying to salvage our company's reputation on that matter.