Here's a really interesting experiment I just did. I set ulimit -u to 50 and restarted mysql. It worked fine until max_used_connectsion and the number of sleeping/persistent connections got up to 45, then it started throwing off the "Can't create thread" error. Then I did ulimit -u 150 and restarted mysql again. This time is worked fine until used_connectsion and the number of sleeping/persistent connections got up to 145, and then it started giving the error. Then I set ulimit -u to unlimited and restarted mysql, and now it's working fine at all load levels. So there seems to be an n-5 rule at work, i.e., whatever ulimit -u is set to minus 5 is the "ceiling" on max_used_connectsion and the number of sleeping/persistent connections. When high load tries to exceed this ceiling, the "Can't create thread" error begins to rear its ugly head.
Also consistent with this theory: the default on my system for ulimit -u is 256, which would explain why in my initial post the "ceiling" I was complaining about was 251.
Good luck to anyone in the future who has this same problem. I hope you are able to find this thread in the archives!
Mike
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