Same chips, same model Dell Poweredge actually. The process is pretty much the same between the local and offsite replicas, we have a home-brew script that runs an rsync from the master to the replica. On the local replica, it then takes the machine out of pacemaker standby, on the offsite replica it starts up postgres directly.
One thought we had today. There is a chance some local crons and some monitoring scripts might be attempting to run queries on the DB during the migration. Is there any chance that could foul something up? its the one difference we could think of after a brainstorming session here. We are going to attempt another test this evening with all crons disabled and monitoring disabled.

Innovation That Protects
On 08/15/2016 08:04 AM, Pete Fuller wrote:
We have not found any obvious differences, other than the size of the
databases (~ 100 gig on the testing site vs 400 Gig in production). In
fact, the upgrade path seems to work with our production db when testing
on our offsite replica that lives in our backup datacenter, near
identical hardware and setup with same install scripts.
Idea that popped into head, how do you get the data to the dbs in the offsite replica versus how do you get the data to the live replica?
Also are all the machines running the same chip architecture?
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Adrian Klaver
adrian.klaver@aklaver.com