I'll admit that I haven't read each post in this thread, just skimmed some. But, I adopt a tinfoil hat philosophy of tossing drives once they start throwing errors, reallocating sectors, or making any physical noise (if relevant) that's unusual. Of course, I'm not fond of losing $ 100 - $200 for a drive. But, I'm even more not fond of losing 1 - 2 TB of data.
May your bits be stable and your interfaces be fast.
Ron
Backups, always.
In my case, the stack of drives I have are from a NAS system, specifically, synology. I can't speak for other NAS brands, but synology throws error messages a little prematurely, imo. I've had errors appear in synology that state the drive has bad sectors and that it should be replaced immediately. Since the data in question is part of a raid6 (again, in my scenario) AND I have a backup of the data in two additional places, I decide to roll the dice and leave the drive in the NAS. Years later, that drive has never thrown another error (at least synology hasn't given me an error for that drive) and it is still in operation as we speak.
If you replaced a drive each time synology threw an error, I guarantee you that you would change your opinion on tossing drives.
I've also had drives, in a synology NAS, that simply stop responding and appearing in synology. The array immediately goes into error mode and I replace the failed drive. In all my attempts with that drive, I was not able to get it to come back online. That's when I'm glad I have a raid and happy to have backups because not all drive errors can be ignored. I had no warning with this faulty drive, it just failed and I never got it back online.
Bottom line is, if your data is important/priceless/etc, make sure you don't only have a single copy of the data.
I've scanned 8 drives since the start of this thread. My results so far
1 drive that SR can't process.
3 drives had a single unrecoverable sector (red completed box)
4 drives completed the scan with no errors (green completed box)
0 data loss because of these drives being in a raid array and the data is backed up and offsite.