Best practise would be to backup and restore, though clearly that comes with downtime, but its the best way of safeguarding the data against corruption.
3tb isn't really a lot of data.
Admittedly iam guilty of performing the old disk shifteroo![]()
Does that raid controller support expanding the array size?
Online Capacity Expansion (OCE) can be done in two ways. If there is a single virtual disk in a disk group and free space is available, the virtual disk´s capacity can be expanded within that free space. If a virtual disk is created and it does not use the maximum size of the disk group, free space is available. Free space is also available when a disk group´s physical disks are replaced by larger disks using the Replace Member feature. A virtual disk's capacity can also be expanded by performing an OCE operation to add more physical disks.
Insert drive HOT (never power down to replace or introduce a hot-swappable drive)
Launch OMSA, make sure it shows under Physical Disks as "ready" (not foreign)
go to storage, PERC, Virtual disks, choose Reconfigure from dropdown menu for RAID 5
The disk will be added to the RAID 5
Since when? I've seen multiple raid 5 arrays with drives exceeding 1TB...