crewly 1.8.3 → 1.8.5

package/dist/backend/backend/src/services/core/system-health.util.js

@@ -6,6 +6,7 @@
  * @module services/core/system-health.util
  */
 import * as os from 'os';
+import { execSync } from 'child_process';
 /**
  * Memory pressure thresholds.
  *
@@ -22,11 +23,105 @@ import * as os from 'os';
  * A fresh Claude Code process is ~150-200MB RSS; reserve 300MB so we
  * never spawn into an actual OOM situation while letting the cache-
  * inflated 95-99% percent reading pass.
+ *
+ * Steve 2026-05-22 dogfood follow-up: even with the 300MB floor, the
+ * gate fires constantly on macOS because `os.freemem()` only counts
+ * STRICTLY-FREE pages — it excludes inactive + speculative pages that
+ * the kernel can reclaim on demand. On a typical Mac with 3GB+ of
+ * reclaimable cache, os.freemem() routinely reports 50-200MB while
+ * Activity Monitor / `vm_stat` show 3-4GB available. The reconciler
+ * was effectively never letting wakes through.
+ *
+ * Real fix: on macOS use `vm_stat` to compute AVAILABLE memory
+ * (free + inactive + speculative), which is what the kernel itself
+ * uses for OOM decisions. Linux's `os.freemem()` is accurate and
+ * keeps the old path.
  */
 export const MEMORY_PRESSURE_SPAWN_THRESHOLD = 90;
 export const MEMORY_PRESSURE_MIN_FREE_MB = 300;
 /** Cached total memory — never changes during process lifetime. */
 const cachedTotalMem = os.totalmem();
+/**
+ * macOS detection. Evaluated on every call rather than captured at
+ * module load — tests need to flip platform after importing.
+ * Runtime overhead is negligible (os.platform is a sync getter).
+ */
+function isDarwin() {
+    return os.platform() === 'darwin';
+}
+/**
+ * Throttled cache of the last `vm_stat` reading on macOS. Parsing
+ * `vm_stat` involves spawning a child process — at the reconciler's
+ * 10-second fast-loop cadence that's tolerable but not free. Hold the
+ * last reading for 1s so back-to-back callers in the same tick don't
+ * each fork.
+ */
+const VM_STAT_CACHE_TTL_MS = 1_000;
+let vmStatCache = null;
+/**
+ * Read macOS `vm_stat` and compute available memory in bytes.
+ *
+ * macOS reports pages in 5 main buckets:
+ *   - free: strictly unused, OS can hand out immediately
+ *   - speculative: prefetched file pages, reclaimable instantly
+ *   - inactive: pages not recently used, reclaimable on demand
+ *   - active: hot working set — NOT reclaimable cheaply
+ *   - wired: kernel/pinned — never reclaimable
+ *
+ * "Available" = free + speculative + inactive. This matches what the
+ * kernel uses when deciding OOM pressure, and what Activity Monitor
+ * shows as "Cached Files + Free" headroom.
+ *
+ * Returns null on any parse failure so the caller can fall back to
+ * `os.freemem()` (overly pessimistic but safe — we'd just over-gate,
+ * not under-gate, in the worst case).
+ */
+function readMacFreeMemBytes() {
+    try {
+        const cached = vmStatCache;
+        if (cached && Date.now() - cached.at < VM_STAT_CACHE_TTL_MS) {
+            return cached.freeMB * 1024 * 1024;
+        }
+        // -c 1 reports a single sample; default is incremental. Trying to
+        // be conservative about runtime — vm_stat with no args takes ~50ms,
+        // -c 1 with no interval is essentially instant.
+        const out = execSync('vm_stat', { timeout: 1_000, encoding: 'utf8' });
+        // First line is the page size: "Mach Virtual Memory Statistics: (page size of 16384 bytes)"
+        const pageSizeMatch = out.match(/page size of (\d+) bytes/);
+        const pageSize = pageSizeMatch ? Number(pageSizeMatch[1]) : 4096;
+        const grab = (label) => {
+            const m = out.match(new RegExp(`Pages ${label}[^:]*:\\s+(\\d+)`));
+            return m ? Number(m[1]) : 0;
+        };
+        const freePages = grab('free');
+        const inactivePages = grab('inactive');
+        const specPages = grab('speculative');
+        const availableBytes = (freePages + inactivePages + specPages) * pageSize;
+        vmStatCache = { freeMB: availableBytes / 1024 / 1024, at: Date.now() };
+        return availableBytes;
+    }
+    catch {
+        return null;
+    }
+}
+/**
+ * Get the platform-appropriate free-memory reading in bytes.
+ *
+ * Exposed for tests; production callers should use {@link getMemoryStats}
+ * or {@link isUnderMemoryPressure} instead.
+ *
+ * @returns free memory in bytes; falls back to os.freemem() if the
+ *   macOS vm_stat parse fails.
+ */
+export function getAvailableMemoryBytes() {
+    if (isDarwin()) {
+        const mac = readMacFreeMemBytes();
+        if (mac !== null)
+            return mac;
+        // Fall through to os.freemem() — conservative but safe.
+    }
+    return os.freemem();
+}
 /**
  * Check if the system is under memory pressure.
  *
@@ -34,17 +129,17 @@ const cachedTotalMem = os.totalmem();
  *   - usedPercent >= MEMORY_PRESSURE_SPAWN_THRESHOLD (90%), AND
  *   - freeMB < MEMORY_PRESSURE_MIN_FREE_MB (300MB)
  *
- * macOS file-cache inflation makes the percent reading misleading on
- * its own. Requiring the absolute-free-MB floor catches the actual
- * OOM-risk case (low real headroom) without permanently blocking
- * spawns on machines that simply have a hot file cache.
+ * On macOS, "free" includes reclaimable inactive+speculative pages
+ * (parsed from `vm_stat`) — without this the reading is ~50MB on a
+ * Mac that actually has gigabytes of headroom, and the gate would
+ * fire constantly. See module-doc comment for the dogfood history.
  *
  * @returns true if system should NOT spawn new processes
  */
 export function isUnderMemoryPressure() {
     if (cachedTotalMem === 0)
         return false;
-    const free = os.freemem();
+    const free = getAvailableMemoryBytes();
     const usedPercent = ((cachedTotalMem - free) / cachedTotalMem) * 100;
     const freeMB = free / 1024 / 1024;
     // Both conditions must hold — percent is a soft signal, free-MB is
@@ -59,11 +154,15 @@ export function isUnderMemoryPressure() {
 export function getMemoryStats() {
     if (cachedTotalMem === 0)
         return { totalMB: 0, freeMB: 0, usedPercent: 0 };
-    const free = os.freemem();
+    const free = getAvailableMemoryBytes();
     return {
         totalMB: Math.round(cachedTotalMem / 1024 / 1024),
         freeMB: Math.round(free / 1024 / 1024),
         usedPercent: Math.round(((cachedTotalMem - free) / cachedTotalMem) * 100 * 10) / 10,
     };
 }
+/** Reset the vm_stat cache — test affordance. */
+export function _resetVmStatCacheForTesting() {
+    vmStatCache = null;
+}
 //# sourceMappingURL=system-health.util.js.map

package/dist/backend/backend/src/services/core/system-health.util.js.map

@@ -1 +1 @@
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package/dist/backend/backend/src/services/session/pty/pty-session.d.ts

@@ -6,7 +6,35 @@
  *
  * @module pty-session
  */
+import * as pty from 'node-pty';
 import type { ISession, SessionOptions } from '../session-backend.interface.js';
+export declare function _setPtySpawnImplForTesting(impl: typeof pty.spawn): () => void;
+/**
+ * Wraps `pty.spawn` with retry-on-transient + actionable error.
+ *
+ * On the 4th and final failure, throws `PtySpawnExhaustedError` with a
+ * human-readable message + machine-readable diagnostics. Callers should
+ * surface the .message to the user (e.g. ORC → Slack).
+ */
+declare class PtySpawnExhaustedError extends Error {
+    readonly diagnostics: {
+        attempts: number;
+        lastError: string;
+        userProcessCount: number | null;
+        maxProcPerUid: number | null;
+        command: string;
+        platform: string;
+    };
+    constructor(message: string, diagnostics: {
+        attempts: number;
+        lastError: string;
+        userProcessCount: number | null;
+        maxProcPerUid: number | null;
+        command: string;
+        platform: string;
+    });
+}
+export { PtySpawnExhaustedError };
 /**
  * PTY Session implementation using node-pty.
  *

package/dist/backend/backend/src/services/session/pty/pty-session.d.ts.map

@@ -1 +1 @@
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package/dist/backend/backend/src/services/session/pty/pty-session.js

@@ -11,6 +11,152 @@ import { execSync } from 'child_process';
 import { DEFAULT_TERMINAL_COLS, DEFAULT_TERMINAL_ROWS, } from '../session-backend.interface.js';
 import { PTY_CONSTANTS } from '../../../constants.js';
 import { LoggerService } from '../../core/logger.service.js';
+/**
+ * Test affordance: lets `pty-session.test.ts` swap in a stub instead of
+ * calling the real `pty.spawn`. Production code path is identical.
+ */
+let ptySpawnImpl = pty.spawn;
+export function _setPtySpawnImplForTesting(impl) {
+    const previous = ptySpawnImpl;
+    ptySpawnImpl = impl;
+    return () => {
+        ptySpawnImpl = previous;
+    };
+}
+/**
+ * Retry policy for transient `pty.spawn` failures. The native node-pty
+ * binding throws a generic `Error("posix_spawnp failed.")` with no errno
+ * detail — on macOS this is usually EAGAIN (process table briefly
+ * saturated by Chrome helpers / VS Code extensions / build spawns) and
+ * retrying after a short pause succeeds. We give up after the 4th
+ * attempt and throw a richer diagnostic.
+ *
+ * Sync sleep uses `Atomics.wait` on an ephemeral SharedArrayBuffer —
+ * blocks the thread without spawning a `sleep(1)` subprocess (which
+ * would compound the very problem we're working around).
+ */
+const PTY_SPAWN_RETRY_BACKOFFS_MS = [0, 150, 400, 1000];
+const PTY_TRANSIENT_ERROR_MARKERS = [
+    'posix_spawnp',
+    'EAGAIN',
+    'ENOMEM',
+    'EMFILE',
+    'ENFILE',
+];
+function isTransientSpawnError(err) {
+    const msg = err instanceof Error ? err.message : String(err);
+    return PTY_TRANSIENT_ERROR_MARKERS.some((m) => msg.includes(m));
+}
+function syncSleepMs(ms) {
+    if (ms <= 0)
+        return;
+    const buf = new SharedArrayBuffer(4);
+    const view = new Int32Array(buf);
+    // Wait returns 'timed-out' after `ms` regardless of view[0] (which
+    // nobody writes to). This is the modern synchronous sleep pattern
+    // recommended for situations where a busy-wait would burn CPU.
+    Atomics.wait(view, 0, 0, ms);
+}
+/**
+ * Read current user process count cheaply. Used in the spawn-failure
+ * diagnostic to tell the user if they're near macOS `kern.maxprocperuid`.
+ */
+function readUserProcessCount() {
+    try {
+        const out = execSync('ps -u "$(id -un)" 2>/dev/null | wc -l', {
+            encoding: 'utf8',
+            timeout: 800,
+        });
+        const n = parseInt(out.trim(), 10);
+        return Number.isFinite(n) ? n : null;
+    }
+    catch {
+        return null;
+    }
+}
+/** Read kern.maxprocperuid. macOS-specific; returns null on non-Darwin. */
+function readMaxProcPerUid() {
+    if (process.platform !== 'darwin')
+        return null;
+    try {
+        const out = execSync('sysctl -n kern.maxprocperuid', {
+            encoding: 'utf8',
+            timeout: 500,
+        });
+        const n = parseInt(out.trim(), 10);
+        return Number.isFinite(n) ? n : null;
+    }
+    catch {
+        return null;
+    }
+}
+/**
+ * Wraps `pty.spawn` with retry-on-transient + actionable error.
+ *
+ * On the 4th and final failure, throws `PtySpawnExhaustedError` with a
+ * human-readable message + machine-readable diagnostics. Callers should
+ * surface the .message to the user (e.g. ORC → Slack).
+ */
+class PtySpawnExhaustedError extends Error {
+    diagnostics;
+    constructor(message, diagnostics) {
+        super(message);
+        this.diagnostics = diagnostics;
+        this.name = 'PtySpawnExhaustedError';
+    }
+}
+function spawnPtyWithRetry(command, args, options, logger) {
+    let lastError = null;
+    for (let attempt = 0; attempt < PTY_SPAWN_RETRY_BACKOFFS_MS.length; attempt++) {
+        const backoffMs = PTY_SPAWN_RETRY_BACKOFFS_MS[attempt];
+        if (backoffMs > 0) {
+            logger.warn('PTY spawn retry — sleeping then retrying', {
+                attempt,
+                backoffMs,
+                command,
+            });
+            syncSleepMs(backoffMs);
+        }
+        try {
+            return ptySpawnImpl(command, args, options);
+        }
+        catch (err) {
+            lastError = err;
+            if (!isTransientSpawnError(err)) {
+                // Non-transient (e.g. ENOENT — command not found): fail fast.
+                throw err;
+            }
+            // Else loop — backoff already happened next iter.
+        }
+    }
+    // Exhausted retries — build an actionable message.
+    const userProcessCount = readUserProcessCount();
+    const maxProcPerUid = readMaxProcPerUid();
+    const errMsg = lastError instanceof Error ? lastError.message : String(lastError);
+    let humanHint = '';
+    if (userProcessCount !== null &&
+        maxProcPerUid !== null &&
+        userProcessCount > maxProcPerUid * 0.75) {
+        humanHint = ` Your user process count is ${userProcessCount} / ${maxProcPerUid} (>75% of limit). Close some Chrome tabs / VS Code windows / other agent sessions and retry.`;
+    }
+    else if (process.platform === 'darwin') {
+        humanHint =
+            ' Likely a transient kernel-level process-table spike (Chrome / VS Code / build tools spawning many helpers). Wait ~30 s and the next attempt should succeed; the OSS will auto-retry on the next user trigger.';
+    }
+    else {
+        humanHint = ' Transient spawn failure — retry shortly.';
+    }
+    const message = `PTY spawn failed after ${PTY_SPAWN_RETRY_BACKOFFS_MS.length} attempts (${errMsg}).${humanHint}`;
+    throw new PtySpawnExhaustedError(message, {
+        attempts: PTY_SPAWN_RETRY_BACKOFFS_MS.length,
+        lastError: errMsg,
+        userProcessCount,
+        maxProcPerUid,
+        command,
+        platform: process.platform,
+    });
+}
+export { PtySpawnExhaustedError };
 /**
  * PTY Session implementation using node-pty.
  *
@@ -97,14 +243,18 @@ export class PtySession {
             TERM: 'xterm-256color',
         };
         try {
-            // Spawn the PTY process
-            this.ptyProcess = pty.spawn(options.command, options.args ?? [], {
+            // Spawn the PTY process — wrapped in retry-with-backoff so that
+            // transient `posix_spawnp failed` errors (typical on macOS when
+            // Chrome / VS Code briefly saturate the process table) don't
+            // turn into user-visible spawn failures. See spawnPtyWithRetry
+            // for the policy + sync sleep pattern.
+            this.ptyProcess = spawnPtyWithRetry(options.command, options.args ?? [], {
                 name: 'xterm-256color',
                 cols: options.cols ?? DEFAULT_TERMINAL_COLS,
                 rows: options.rows ?? DEFAULT_TERMINAL_ROWS,
                 cwd: options.cwd,
                 env: sessionEnv,
-            });
+            }, this.logger);
             this.logger.info('PTY process spawned successfully', {
                 name,
                 pid: this.ptyProcess.pid,
@@ -112,11 +262,19 @@ export class PtySession {
             });
         }
         catch (spawnError) {
+            // `PtySpawnExhaustedError` carries the actionable hint already
+            // in its .message; other errors (e.g. ENOENT — command not
+            // found) propagate as-is. Either way we log richer context.
+            const errMsg = spawnError instanceof Error ? spawnError.message : String(spawnError);
+            const diagnostics = spawnError instanceof PtySpawnExhaustedError
+                ? spawnError.diagnostics
+                : undefined;
             this.logger.error('Failed to spawn PTY process', {
                 name,
                 command: options.command,
                 cwd: options.cwd,
-                error: spawnError instanceof Error ? spawnError.message : String(spawnError),
+                error: errMsg,
+                diagnostics,
                 stack: spawnError instanceof Error ? spawnError.stack : undefined,
             });
             throw spawnError;

package/dist/backend/backend/src/services/session/pty/pty-session.js.map

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package/dist/backend/backend/src/services/task-pool/task-pool.service.d.ts

@@ -483,6 +483,26 @@ export declare class TaskPoolService {
      * @throws Error if work item not found or not in 'running' status
      */
     failItem(workItemId: string, error: string): Promise<void>;
+    /**
+     * Requeue a failed WorkItem back to `queued` for another attempt.
+     *
+     * Path: `failed → queued` (legal in WORK_ITEM_TRANSITIONS but previously
+     * unused — the system never auto-retried, every failure was terminal).
+     * Increments `retryCount`, clears `startedAt`, preserves `target` so
+     * the same agent gets a second shot, and records the previous error
+     * on the WI's metadata for postmortem visibility.
+     *
+     * Caller must have ALREADY confirmed `retryCount < maxRetries` — this
+     * method does NOT enforce the cap, on the assumption that the caller
+     * (v3-data.onTaskFailed) handles the exhausted-retries branch with
+     * escalation to ORC.
+     *
+     * @param workItemId - The failed WI to retry
+     * @param reason     - Why the previous attempt failed (recorded on
+     *   metadata.lastFailureReason; surfaces in the activity timeline)
+     * @throws if the WI doesn't exist or isn't in `failed` status
+     */
+    requeueAfterFailure(workItemId: string, reason: string): Promise<void>;
     /**
      * Processes a heartbeat from an agent for their active claim.
      *

package/dist/backend/backend/src/services/task-pool/task-pool.service.d.ts.map

@@ -1 +1 @@
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package/dist/backend/backend/src/services/task-pool/task-pool.service.js

@@ -1004,6 +1004,67 @@ export class TaskPoolService {
         await this.storage.flush();
         this.logger.info('WorkItem failed', { workItemId, error });
     }
+    /**
+     * Requeue a failed WorkItem back to `queued` for another attempt.
+     *
+     * Path: `failed → queued` (legal in WORK_ITEM_TRANSITIONS but previously
+     * unused — the system never auto-retried, every failure was terminal).
+     * Increments `retryCount`, clears `startedAt`, preserves `target` so
+     * the same agent gets a second shot, and records the previous error
+     * on the WI's metadata for postmortem visibility.
+     *
+     * Caller must have ALREADY confirmed `retryCount < maxRetries` — this
+     * method does NOT enforce the cap, on the assumption that the caller
+     * (v3-data.onTaskFailed) handles the exhausted-retries branch with
+     * escalation to ORC.
+     *
+     * @param workItemId - The failed WI to retry
+     * @param reason     - Why the previous attempt failed (recorded on
+     *   metadata.lastFailureReason; surfaces in the activity timeline)
+     * @throws if the WI doesn't exist or isn't in `failed` status
+     */
+    async requeueAfterFailure(workItemId, reason) {
+        const workItem = await this.storage.findWorkItem(workItemId);
+        if (!workItem) {
+            throw new Error(`WorkItem not found: ${workItemId}`);
+        }
+        if (workItem.status !== 'failed') {
+            throw new Error(`Cannot requeue WorkItem after failure: status must be 'failed', got '${workItem.status}'`);
+        }
+        await this.transitionStatus(workItemId, 'queued', 'system', (wi) => {
+            wi.retryCount += 1;
+            wi.startedAt = undefined;
+            wi.completedAt = undefined;
+            // Keep `target` — the original agent should get the retry.
+            // APPEND to failureHistory so postmortems see all attempts, not
+            // just the most recent. `lastFailureReason` / `lastFailureAt`
+            // are retained for back-compat with dashboards that already
+            // read those scalar fields. Cap history at 10 entries so a
+            // pathological retry loop can't bloat the metadata indefinitely.
+            const now = new Date().toISOString();
+            const priorHistory = wi.metadata?.failureHistory ?? [];
+            wi.metadata = {
+                ...(wi.metadata ?? {}),
+                failureHistory: [
+                    ...priorHistory,
+                    { at: now, reason, retryAttempt: wi.retryCount },
+                ].slice(-10),
+                lastFailureReason: reason,
+                lastFailureAt: now,
+                retryAttempt: wi.retryCount,
+            };
+            // Clear the error field so a successful retry doesn't surface a
+            // stale error message; the metadata above keeps the history.
+            wi.error = undefined;
+        });
+        await this.storage.flush();
+        this.logger.info('WorkItem requeued after failure', {
+            workItemId,
+            retryCount: workItem.retryCount + 1,
+            maxRetries: workItem.maxRetries,
+            reason,
+        });
+    }
     // -----------------------------------------------------------------------
     // Claim Lifecycle (delegated to ClaimService)
     // -----------------------------------------------------------------------