sensorium-mcp 3.1.0-refactor.1 → 3.1.0-refactor.4

package/dist/services/thread-lifecycle.service.js.map

@@ -1 +1 @@
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package/dist/services/worker-cleanup.service.d.ts

@@ -1,4 +1,15 @@
 import { type ThreadLifecycleService } from "./thread-lifecycle.service.js";
+export declare const WORKER_GRACE_MS: number;
+/** True while a worker is inside its TTL grace window (winding down, but its MCP
+ *  socket is still open so it can deliver a final result). Read by the poll loop
+ *  (to tell the worker to wrap up) and by send_message_to_thread (to honestly
+ *  reject new orchestrator work rather than silently queue it to a dying worker). */
+export declare function isWorkerInGrace(threadId: number): boolean;
+/** Drop a worker's grace-map entry without running teardown. Used by the terminal
+ *  self-exit path in handleProcessExit, which returns without calling
+ *  decommissionWorker (the DB row is already Archived/Expired) and would otherwise
+ *  leak the in-memory deadline forever. Best-effort and safe if no entry exists. */
+export declare function clearWorkerGrace(threadId: number): void;
 export declare function decommissionWorker(thread: {
     threadId: number;
     pid?: number;
@@ -13,6 +24,7 @@ export declare function decommissionWorker(thread: {
     chatId: string;
     threadLifecycle: ThreadLifecycleService;
 }): Promise<void>;
+export declare const DEFAULT_WORKER_TTL_MS: number;
 export declare function cleanupExpiredWorkers(db: ReturnType<typeof import("../data/memory/index.js").initMemoryDb>, telegram: {
     deleteForumTopic(chatId: string, threadId: number): Promise<void>;
     sendMessage?(chatId: string, text: string, parseMode?: string, threadId?: number): Promise<void>;

package/dist/services/worker-cleanup.service.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"worker-cleanup.service.d.ts","sourceRoot":"","sources":["../../src/services/worker-cleanup.service.ts"],"names":[],"mappings":"AAgBA,OAAO,EAAe,KAAK,sBAAsB,EAAE,MAAM,+BAA+B,CAAC;AAyBzF,eAAO,MAAM,eAAe,QAGxB,CAAC;AAQL;;;qFAGqF;AACrF,wBAAgB,eAAe,CAAC,QAAQ,EAAE,MAAM,GAAG,OAAO,CAEzD;AAED;;;oFAGoF;AACpF,wBAAgB,gBAAgB,CAAC,QAAQ,EAAE,MAAM,GAAG,IAAI,CAEvD;AAED,wBAAsB,kBAAkB,CACtC,MAAM,EAAE;IACN,QAAQ,EAAE,MAAM,CAAC;IACjB,GAAG,CAAC,EAAE,MAAM,CAAC;IACb,oBAAoB,CAAC,EAAE,MAAM,CAAC;IAC9B,IAAI,EAAE,MAAM,CAAC;IACb,SAAS,CAAC,EAAE,MAAM,CAAC;CACpB,EACD,IAAI,EAAE;IACJ,EAAE,EAAE,UAAU,CAAC,cAAc,yBAAyB,EAAE,YAAY,CAAC,CAAC;IACtE,QAAQ,EAAE;QAAE,gBAAgB,CAAC,MAAM,EAAE,MAAM,EAAE,QAAQ,EAAE,MAAM,GAAG,OAAO,CAAC,IAAI,CAAC,CAAA;KAAE,CAAC;IAChF,MAAM,EAAE,MAAM,CAAC;IACf,eAAe,EAAE,sBAAsB,CAAC;CACzC,GACA,OAAO,CAAC,IAAI,CAAC,CAsGf;AAoED,eAAO,MAAM,qBAAqB,QAAiB,CAAC;AA2JpD,wBAAsB,qBAAqB,CACzC,EAAE,EAAE,UAAU,CAAC,cAAc,yBAAyB,EAAE,YAAY,CAAC,EACrE,QAAQ,EAAE;IACR,gBAAgB,CAAC,MAAM,EAAE,MAAM,EAAE,QAAQ,EAAE,MAAM,GAAG,OAAO,CAAC,IAAI,CAAC,CAAC;IAClE,WAAW,CAAC,CACV,MAAM,EAAE,MAAM,EACd,IAAI,EAAE,MAAM,EACZ,SAAS,CAAC,EAAE,MAAM,EAClB,QAAQ,CAAC,EAAE,MAAM,GAChB,OAAO,CAAC,IAAI,CAAC,CAAC;CAClB,EACD,MAAM,EAAE,MAAM,EACd,eAAe,EAAE,sBAAsB,EACvC,KAAK,GAAE,MAA8B,GACpC,OAAO,CAAC;IAAE,OAAO,EAAE,MAAM,CAAC;IAAC,MAAM,EAAE,MAAM,EAAE,CAAA;CAAE,CAAC,CAwThD"}

package/dist/services/worker-cleanup.service.js

@@ -2,7 +2,7 @@ import { unlinkSync, readFileSync, writeFileSync, renameSync } from "node:fs";
 import { join } from "node:path";
 import { archiveNotesForThread } from "../data/memory/note-archival.js";
 import { closeThreadSessions } from "../sessions/mcp-registry.js";
-import { getExplicitTelegramTopicId } from "../data/memory/thread-registry.js";
+import { getExplicitTelegramTopicId, updateThread } from "../data/memory/thread-registry.js";
 import { errorMessage } from "../lib/utils.js";
 import { spawnedThreads, readPidFiles, killProcessTree, isProcessAlive, clearTaskConsumed, deletePendingTaskMailbox, PROCESS_BASE_DIR, } from "./process.service.js";
 import { ThreadState } from "./thread-lifecycle.service.js";
@@ -12,7 +12,50 @@ import { log } from "../lib/logger.js";
 function topicAlreadyGone(msg) {
     return /TOPIC_ID_INVALID|message thread not found/i.test(msg);
 }
+// ── Worker TTL grace window ─────────────────────────────────────────────────
+// When a worker crosses its 1h TTL we do NOT force-kill it on the spot. The
+// first sweep that finds it past-TTL instead puts it into a GRACE window: its
+// MCP socket is left OPEN so the worker can finish its current turn and deliver
+// its final result to the orchestrator (via send_message_to_thread). A LATER
+// sweep, once the grace deadline has passed, runs the full teardown.
+//
+// WORKER_GRACE_MS is a MINIMUM, not a precise teardown deadline. Phase 1 (enter
+// grace) and Phase 2 (teardown) each require a separate cleanup sweep, and the
+// sweep runs on a fixed cadence (WORKER_CLEANUP_INTERVAL_MS in background-runner,
+// ~5 min). So the grace window is quantized up to the next sweep boundary: the
+// effective teardown of a worker that never delivers is bounded by TTL + grace
+// rounded up to ~1–2 sweep intervals — worst case on the order of 5–10 min past
+// TTL, never unbounded. A well-behaved worker self-exits within seconds of the
+// wrap-up signal and never waits for Phase 2. The TTL itself is unchanged; grace
+// only adds a bounded clean-shutdown tail. Override 60s via WORKER_GRACE_SECONDS.
+export const WORKER_GRACE_MS = (() => {
+    const s = Number(process.env.WORKER_GRACE_SECONDS);
+    return Number.isFinite(s) && s > 0 ? s * 1000 : 60_000;
+})();
+// threadId → absolute ms deadline after which the full teardown runs. In-memory
+// only: on a server restart the map is empty, so a still-past-TTL worker simply
+// re-enters grace on the next sweep and is cleaned up then — it can never get
+// stuck un-cleaned. The hard TTL+grace cap resets at worst once per restart.
+const workerGraceDeadlines = new Map();
+/** True while a worker is inside its TTL grace window (winding down, but its MCP
+ *  socket is still open so it can deliver a final result). Read by the poll loop
+ *  (to tell the worker to wrap up) and by send_message_to_thread (to honestly
+ *  reject new orchestrator work rather than silently queue it to a dying worker). */
+export function isWorkerInGrace(threadId) {
+    return workerGraceDeadlines.has(threadId);
+}
+/** Drop a worker's grace-map entry without running teardown. Used by the terminal
+ *  self-exit path in handleProcessExit, which returns without calling
+ *  decommissionWorker (the DB row is already Archived/Expired) and would otherwise
+ *  leak the in-memory deadline forever. Best-effort and safe if no entry exists. */
+export function clearWorkerGrace(threadId) {
+    workerGraceDeadlines.delete(threadId);
+}
 export async function decommissionWorker(thread, deps) {
+    // Grace is over the moment full teardown begins — drop any deadline so the map
+    // never retains a stale entry (also covers the self-exit path where the worker
+    // exited during grace and handleProcessExit decommissions it directly).
+    workerGraceDeadlines.delete(thread.threadId);
     // 0. Mark thread as Exiting so the state machine reflects teardown-in-progress
     try {
         deps.threadLifecycle.transitionThread(deps.db, thread.threadId, ThreadState.Exiting);
@@ -20,23 +63,54 @@ export async function decommissionWorker(thread, deps) {
     catch (err) {
         log.warn(`[decommission] transitionThread failed for ${thread.threadId}: ${errorMessage(err)}`);
     }
-    // 1. Close MCP transport(s) so the agent's event loop drains and its process
-    //    exits ON ITS OWN. A server's own child cannot be reliably force-killed on
-    //    Windows (parent→child EPERM), but the server owns the socket — closing it
-    //    is the reliable teardown. The kill below stays as a fast-path backstop.
-    try {
-        const closed = closeThreadSessions(thread.threadId);
-        if (closed > 0)
-            log.info(`[decommission] Closed ${closed} MCP transport(s) for thread ${thread.threadId}.`);
+    // 1. Kill the process FIRST (no-op if already dead). We must confirm the agent
+    //    is gone before touching its MCP transport. Closing the socket of a LIVE
+    //    agent we could NOT kill (EPERM on a server's own Windows child) does NOT
+    //    make a mid-task agent self-exit — it just ORPHANS it: alive, but with no
+    //    MCP connection → wedged forever. So kill, then close only if confirmed dead.
+    //    Routed through the same circuit breaker as the backstop reaper: this path
+    //    re-runs for an unkillable worker on every other sweep (Phase 1 re-enters
+    //    grace, Phase 2 kills again), so leaving it unthrottled would keep feeding
+    //    the very starvation the breaker exists to stop. Skipping the kill lands on
+    //    the identical "still alive" branch below as a failed kill would.
+    let killIssued = false;
+    if (thread.pid !== undefined) {
+        killIssued = await killWorkerWithBackoff(thread.pid, thread.threadId, "decommission", thread.startedAt, Date.now());
     }
-    catch (err) {
-        log.warn(`[decommission] closeThreadSessions failed for ${thread.threadId}: ${errorMessage(err)}`);
+    // 2. Tear down MCP transport(s) ONLY once the process is confirmed dead. A dead
+    //    process's socket is already gone, so this is bookkeeping (and marks the
+    //    close expected so http-server's onclose does not re-kill). If the kill
+    //    EPERM-failed and the agent is still alive, LEAVE the transport OPEN so the
+    //    live agent stays connected and functional instead of being orphaned — an
+    //    idle unkillable worker simply stays parked in wait, which is harmless.
+    const processGone = thread.pid === undefined || !isProcessAlive(thread.pid, thread.startedAt);
+    if (processGone) {
+        // Process confirmed gone — drop the unkillable anchor and the breaker entry so
+        // neither outlives the thread (and a future thread reusing this id starts clean).
+        clearUnkillableAttempt(thread.threadId);
+        try {
+            const closed = closeThreadSessions(thread.threadId);
+            if (closed > 0)
+                log.info(`[decommission] Closed ${closed} MCP transport(s) for thread ${thread.threadId}.`);
+        }
+        catch (err) {
+            log.warn(`[decommission] closeThreadSessions failed for ${thread.threadId}: ${errorMessage(err)}`);
+        }
     }
-    // 2. Kill process (no-op if already dead)
-    if (thread.pid !== undefined) {
-        await killProcessTree(thread.pid, thread.threadId, "decommission", thread.startedAt);
+    else {
+        // Kill EPERM-failed and the agent is still alive. Abort teardown entirely:
+        // deleting the topic, archiving notes/DB, or dropping in-memory tracking now
+        // would erase a RUNNING worker's topic and untrack it while it keeps going.
+        // Leave everything intact (transport already left open above) and return — a
+        // later sweep re-runs decommission and completes it once the process is dead
+        // (the keeper escalates a truly unkillable process in the meantime).
+        log.warn(`[decommission] Worker thread ${thread.threadId} survived kill (still alive) — aborting teardown; topic, notes, DB row and tracking preserved until the process is confirmed dead.`);
+        // Charge the breaker only for a kill this call actually issued.
+        if (thread.pid !== undefined && killIssued)
+            recordKillFailure(thread.pid, thread.threadId);
+        return;
     }
-    // 3. Delete Telegram topic
+    // 3. Delete Telegram topic (reached only when the process is confirmed dead).
     try {
         const topicId = getExplicitTelegramTopicId(deps.db, thread.threadId) ?? thread.threadId;
         await deps.telegram.deleteForumTopic(deps.chatId, topicId);
@@ -129,9 +203,8 @@ async function finalizeDeadWorker(threadId, pidFilePath, db, telegram, chatId, t
         }
     }
 }
-const DEFAULT_WORKER_TTL_MS = 60 * 60 * 1000;
+export const DEFAULT_WORKER_TTL_MS = 60 * 60 * 1000;
 const UNKILLABLE_RENOTIFY_MS = 60 * 60 * 1000; // re-ping the operator at most hourly once the alert threshold is crossed
-let orphanSweepDone = false;
 // How long a worker must resist every kill before we bother the operator. Wedged
 // workers almost always self-thaw and die within seconds-to-minutes (Windows S0
 // Modern Standby freezes background processes; taskkill EPERMs until they wake),
@@ -192,17 +265,91 @@ function recordFirstUnkillableAttempt(threadId, now) {
  *  reuses the id starts its clock fresh. */
 function clearUnkillableAttempt(threadId) {
     unkillableNotifiedAt.delete(threadId);
+    killBackoff.delete(threadId);
     const store = loadUnkillableStore();
     if (store.delete(threadId))
         persistUnkillableStore();
 }
+// ── Kill-retry circuit breaker ─────────────────────────────────────────────
+// A process that EPERMs is not going to yield to the same taskkill five minutes
+// later, but the sweep used to re-issue it every single cycle regardless. Each
+// attempt is a spawned taskkill plus a process-tree walk, and with a couple of
+// wedged workers that was enough to starve the sweep itself — the scheduler went
+// quiet for hours while the loop did nothing but re-kill the unkillable.
+//
+// So: try hard a few times (most wedged workers thaw and die within minutes),
+// then back off to an occasional retry. Liveness is still checked every sweep —
+// only the kill is throttled — so a worker that thaws and exits on its own is
+// still reaped promptly.
+const UNKILLABLE_MAX_FAST_ATTEMPTS = 5;
+const UNKILLABLE_RETRY_BACKOFF_MS = 30 * 60 * 1000;
+// An entry in real backoff is retried at least every UNKILLABLE_RETRY_BACKOFF_MS,
+// so its lastAttemptAt is never more than ~30m stale. Anything older belongs to a
+// thread that left by a path which never observes its death (pid file removed by
+// hand, exit handler that skips decommission) and would otherwise sit in the map
+// for the life of the process.
+const KILL_BACKOFF_TTL_MS = 24 * 60 * 60 * 1000;
+/** threadId → the pid we have been failing to kill, how many times, and when last. */
+const killBackoff = new Map();
+/** Drop entries no sweep has touched in a day — see {@link KILL_BACKOFF_TTL_MS}. */
+function pruneKillBackoff(now) {
+    for (const [threadId, state] of killBackoff)
+        if (now - state.lastAttemptAt > KILL_BACKOFF_TTL_MS)
+            killBackoff.delete(threadId);
+}
+/**
+ * Kill a worker's process tree unless the circuit breaker says to sit this sweep
+ * out. Returns true when a kill was actually issued — the caller MUST pass that
+ * back to {@link recordKillFailure} if the process survives, and must NOT infer
+ * it from timestamps: sweeps can overlap (setInterval does not wait for the
+ * previous run), so "the recorded attempt is mine" is not something a shared
+ * clock can answer.
+ */
+async function killWorkerWithBackoff(pid, threadId, caller, startedAt, now) {
+    const state = killBackoff.get(threadId);
+    // The failure history belongs to a PID, not to a thread id. A thread that is
+    // torn down and respawned gets a brand-new process which has resisted nothing
+    // and deserves the full fast-attempt budget — otherwise it inherits its
+    // predecessor's 30-minute skip and lingers for no reason.
+    const staleEntry = state !== undefined && state.pid !== pid;
+    if (state !== undefined &&
+        !staleEntry &&
+        state.failures >= UNKILLABLE_MAX_FAST_ATTEMPTS &&
+        now - state.lastAttemptAt < UNKILLABLE_RETRY_BACKOFF_MS) {
+        log.debug(`[worker-cleanup] Worker pid=${pid} thread=${threadId} in kill backoff (${state.failures} failures, last attempt ${Math.round((now - state.lastAttemptAt) / 60000)}m ago) — skipping kill this sweep (caller=${caller}).`);
+        return false;
+    }
+    killBackoff.set(threadId, {
+        pid,
+        failures: staleEntry ? 0 : (state?.failures ?? 0),
+        lastAttemptAt: now,
+    });
+    await killProcessTree(pid, threadId, caller, startedAt);
+    return true;
+}
+/** Count a survived kill against the breaker. Call ONLY when a kill was issued
+ *  (i.e. {@link killWorkerWithBackoff} returned true) and the pid is still alive. */
+function recordKillFailure(pid, threadId) {
+    const state = killBackoff.get(threadId);
+    // A concurrent sweep may have re-keyed the entry onto a different pid; that
+    // process's budget is not ours to spend.
+    if (state === undefined || state.pid !== pid)
+        return;
+    state.failures += 1;
+    if (state.failures === UNKILLABLE_MAX_FAST_ATTEMPTS) {
+        log.warn(`[worker-cleanup] Worker pid=${pid} thread=${threadId} survived ${state.failures} kills — backing off to one retry per ${UNKILLABLE_RETRY_BACKOFF_MS / 60000}m so the sweep is not starved.`);
+    }
+}
 export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycle, ttlMs = DEFAULT_WORKER_TTL_MS) {
     const result = { cleaned: 0, errors: [] };
     const now = Date.now();
+    pruneKillBackoff(now);
     for (const thread of spawnedThreads.filter((t) => t.threadType === "worker" && now - t.createdAt > ttlMs)) {
         try {
-            await cleanupSingleWorker(thread, db, telegram, chatId, threadLifecycle);
-            result.cleaned++;
+            // Two-phase teardown: only counts as "cleaned" once the worker is actually
+            // torn down (Phase 2). Phase 1 just opens the grace window and returns false.
+            if (await cleanupSingleWorker(thread, db, telegram, chatId, threadLifecycle))
+                result.cleaned++;
         }
         catch (err) {
             result.errors.push(`Thread ${thread.threadId}: ${errorMessage(err)}`);
@@ -236,17 +383,11 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
                 const inMemEntry = spawnedThreads.find((t) => t.threadId === row.thread_id);
                 const killPid = pidEntry?.pid ?? inMemEntry?.pid;
                 const killStartedAt = pidEntry?.startedAt ?? inMemEntry?.startedAt;
-                // Close the MCP transport first so the agent process drains and exits on
-                // its own (the reliable teardown; force-kill of a server child is racy on
-                // Windows). killProcessTree below is a best-effort fast-path backstop.
-                try {
-                    const closed = closeThreadSessions(row.thread_id);
-                    if (closed > 0)
-                        log.info(`[worker-cleanup] Closed ${closed} MCP transport(s) for stale worker thread ${row.thread_id}.`);
-                }
-                catch (err) {
-                    log.warn(`[worker-cleanup] closeThreadSessions failed for stale thread ${row.thread_id}: ${errorMessage(err)}`);
-                }
+                // Kill the process FIRST (best-effort). Do NOT close the MCP transport of
+                // a still-live agent: closing a mid-task agent's socket does not make it
+                // self-exit — it orphans it (alive, but no MCP connection → wedged). So
+                // confirm death via the kill, then tear the transport down only in the
+                // confirmed-dead branch below.
                 if (killPid)
                     await killProcessTree(killPid, row.thread_id, "worker-cleanup-expired", killStartedAt);
                 // Invariant: a worker's topic is deleted ONLY when its process is confirmed
@@ -255,6 +396,16 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
                 // here would orphan the topic of a still-running worker.
                 const processGone = !killPid || !isProcessAlive(killPid, killStartedAt);
                 if (processGone) {
+                    // Confirmed dead — its socket is already gone, so closing the transport
+                    // is bookkeeping (and marks the close expected). Safe now.
+                    try {
+                        const closed = closeThreadSessions(row.thread_id);
+                        if (closed > 0)
+                            log.info(`[worker-cleanup] Closed ${closed} MCP transport(s) for stale worker thread ${row.thread_id}.`);
+                    }
+                    catch (err) {
+                        log.warn(`[worker-cleanup] closeThreadSessions failed for stale thread ${row.thread_id}: ${errorMessage(err)}`);
+                    }
                     try {
                         // For workers, thread_id IS the Telegram topic ID (created via createManagedTopic).
                         // Use explicit telegram_topic_id if set, otherwise fall back to thread_id.
@@ -275,7 +426,9 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
                     clearUnkillableAttempt(row.thread_id);
                 }
                 else {
-                    log.warn(`[worker-cleanup] Stale worker thread ${row.thread_id} survived kill — deferring topic deletion to reaper (process still alive).`);
+                    // Left alive by an EPERM kill — leave the MCP transport OPEN (closing it
+                    // would orphan the live agent) and defer topic deletion to the reaper.
+                    log.warn(`[worker-cleanup] Stale worker thread ${row.thread_id} survived kill — leaving its MCP transport open and deferring topic deletion to reaper (process still alive).`);
                 }
                 threadLifecycle.archiveThread(db, row.thread_id);
                 try {
@@ -300,30 +453,51 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
     catch (err) {
         log.warn(`[worker-cleanup] Failed to query stale DB workers: ${errorMessage(err)}`);
     }
-    // One-time sweep: delete orphan Telegram topics for already-archived workers
-    // (legacy bug: telegram_topic_id was not set at registration time).
-    if (!orphanSweepDone)
-        try {
-            orphanSweepDone = true;
-            const orphanRows = db
-                .prepare(`SELECT thread_id, telegram_topic_id FROM thread_registry
-       WHERE type = 'worker' AND status = 'archived'`)
-                .all();
-            for (const row of orphanRows) {
-                const topicId = row.telegram_topic_id ?? row.thread_id;
-                try {
-                    await telegram.deleteForumTopic(chatId, topicId);
-                    result.cleaned++;
-                    log.info(`[worker-cleanup] Deleted orphan topic ${topicId} for archived worker ${row.thread_id}`);
+    // Periodic self-clearing sweep: delete leftover Telegram topics for workers that
+    // are already archived but whose topic was never deleted (e.g. archived via a raw
+    // status update that bypassed the normal decommission/topic-delete path). Safe to
+    // run every cycle: it selects ONLY rows that still carry a topic id, and nulls the
+    // id after a successful (or already-gone) delete, so each orphan is handled once
+    // and the query converges to empty. The `IS NOT NULL` gate guarantees we delete
+    // the EXPLICIT topic id — never the thread_id fallback that once removed a root
+    // topic (see topic-deletion-bug).
+    try {
+        const orphanRows = db
+            .prepare(`SELECT thread_id, telegram_topic_id FROM thread_registry
+         WHERE type = 'worker' AND status = 'archived' AND telegram_topic_id IS NOT NULL`)
+            .all();
+        for (const row of orphanRows) {
+            // Guard against a concurrent unarchive between snapshot and delete: re-read
+            // the row and skip if it is no longer an archived worker still carrying this
+            // exact topic id — otherwise we could delete a just-reactivated worker's topic.
+            const cur = db
+                .prepare(`SELECT status, telegram_topic_id FROM thread_registry WHERE thread_id = ?`)
+                .get(row.thread_id);
+            if (!cur || cur.status !== "archived" || cur.telegram_topic_id !== row.telegram_topic_id)
+                continue;
+            try {
+                await telegram.deleteForumTopic(chatId, row.telegram_topic_id);
+                updateThread(db, row.thread_id, { telegramTopicId: null });
+                result.cleaned++;
+                log.info(`[worker-cleanup] Deleted orphan topic ${row.telegram_topic_id} for archived worker ${row.thread_id}`);
+            }
+            catch (err) {
+                const msg = errorMessage(err);
+                if (topicAlreadyGone(msg)) {
+                    // Already gone IS the desired end state — clear the id so we stop revisiting it.
+                    updateThread(db, row.thread_id, { telegramTopicId: null });
+                    log.info(`[worker-cleanup] Orphan topic for archived worker ${row.thread_id} already gone (${msg}) — cleared.`);
                 }
-                catch {
-                    // Topic already deleted or invalid — ignore
+                else {
+                    // Genuine transient Telegram failure — leave the id set to retry next cycle.
+                    log.warn(`[worker-cleanup] deleteForumTopic failed for archived worker ${row.thread_id} — will retry next cycle: ${msg}`);
                 }
             }
         }
-        catch (err) {
-            log.warn(`[worker-cleanup] Failed to sweep orphan topics: ${errorMessage(err)}`);
-        }
+    }
+    catch (err) {
+        log.warn(`[worker-cleanup] Failed to sweep orphan topics: ${errorMessage(err)}`);
+    }
     // Backstop process reaper: a worker process must be stopped in ANY case once
     // it should no longer be running. The stale-rows path above skips already-
     // archived rows, and the archived-topic sweep never killed the
@@ -339,6 +513,12 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
             const isWorker = entry.threadType === "worker" || row?.type === "worker";
             if (!isWorker)
                 continue;
+            // Respect the TTL grace window: a worker mid-grace is INTENTIONALLY left
+            // alive with its MCP socket open so it can deliver a final result. The
+            // two-phase teardown in cleanupSingleWorker owns killing it once grace
+            // expires — reaping it here would defeat the grace and drop its result.
+            if (isWorkerInGrace(entry.threadId))
+                continue;
             // HARD lifetime cap from created_at (see staleRows above): an idle worker
             // refreshing last_active_at must still die once it outlives ttlMs.
             const pastTtl = row?.ts ? now - new Date(row.ts).getTime() > ttlMs : true;
@@ -354,16 +534,15 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
                 result.cleaned++;
                 continue;
             }
-            // Reliable teardown for the EPERM-unkillable case: an agent that outlived
-            // its thread is still holding an open MCP socket to this server, which is
-            // what keeps its Node event loop alive. Close that socket — the client
-            // gets a FIN, drains, and the process exits ON ITS OWN. This is the fix
-            // for exactly the wedged-child case where killProcessTree hits EPERM.
-            const closedTransports = closeThreadSessions(entry.threadId);
-            if (closedTransports > 0) {
-                log.info(`[worker-cleanup] Closed ${closedTransports} MCP transport(s) for lingering worker thread ${entry.threadId} — awaiting self-exit.`);
-            }
-            await killProcessTree(entry.pid, entry.threadId, "worker-cleanup-reap", entry.startedAt);
+            // Attempt to reap the lingering process. Do NOT close its MCP transport
+            // first: for a BUSY agent the kill can EPERM-fail (a server cannot reliably
+            // kill its own Windows child), and closing the socket of an agent we could
+            // not kill does not make a mid-task agent self-exit — it ORPHANS it (alive,
+            // but with no MCP connection → wedged forever). So kill first; only once the
+            // process is confirmed dead (below) do we tear the transport down.
+            // Skip the kill (not the liveness check) while this pid is in backoff —
+            // see the circuit-breaker note above.
+            const killIssued = await killWorkerWithBackoff(entry.pid, entry.threadId, "worker-cleanup-reap", entry.startedAt, now);
             // killProcessTree resolves even when the kill FAILS (e.g. EPERM on a
             // Windows claude.exe whose wedged bash.exe child makes taskkill /T a
             // no-op). Re-check liveness before claiming success — otherwise we log a
@@ -371,17 +550,20 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
             // hiding a zombie that then reappears and "reaps" forever. If it survived,
             // surface it to the operator (rate-limited) so it gets a manual kill.
             if (isProcessAlive(entry.pid, entry.startedAt)) {
-                // If we JUST closed its socket this pass, the self-exit is still
-                // draining — don't cry "unkillable" yet. Give it until the next sweep;
-                // by then it has either exited (caught above) or is genuinely wedged.
-                if (closedTransports > 0)
-                    continue;
+                // Still alive after an EPERM kill — LEAVE its MCP transport OPEN so the
+                // agent stays connected rather than being orphaned (closing a live agent's
+                // socket does not make it self-exit if it is mid-task). An idle unkillable
+                // worker simply stays parked in wait, which is harmless; it is escalated
+                // to the operator below once it has resisted for the full threshold.
                 const name = row?.name ?? `thread ${entry.threadId}`;
                 // Anchor the clock at the first survived kill (persisted). Keep retrying
                 // silently — most wedged workers thaw and die within minutes. Only once a
                 // worker has resisted for the full threshold do we escalate to Telegram.
                 const firstAttempt = recordFirstUnkillableAttempt(entry.threadId, now);
                 const stuckMs = now - firstAttempt;
+                // Only count a failure for a kill we actually issued.
+                if (killIssued)
+                    recordKillFailure(entry.pid, entry.threadId);
                 if (stuckMs < UNKILLABLE_ALERT_THRESHOLD_MS) {
                     log.debug(`[worker-cleanup] Worker pid=${entry.pid} thread=${entry.threadId} ('${name}') survived kill — stuck ${Math.round(stuckMs / 60000)}m, below alert threshold; retrying silently.`);
                     continue;
@@ -408,8 +590,15 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
                 continue;
             }
             clearUnkillableAttempt(entry.threadId);
+            // Confirmed dead after kill — its socket is already gone, so closing the
+            // transport is bookkeeping (and marks the close expected). Do it now, then
+            // delete the topic (invariant-safe) and finalize.
+            const closedTransports = closeThreadSessions(entry.threadId);
+            if (closedTransports > 0) {
+                log.info(`[worker-cleanup] Closed ${closedTransports} MCP transport(s) for reaped worker thread ${entry.threadId}.`);
+            }
             log.info(`[worker-cleanup] Reaped lingering worker pid=${entry.pid} thread=${entry.threadId} (status=${row?.status ?? "unknown"}, pastTtl=${pastTtl})`);
-            // Confirmed dead after kill — delete the topic (invariant-safe) and finalize.
+            // Delete the topic (invariant-safe) and finalize.
             await finalizeDeadWorker(entry.threadId, entry.filePath, db, telegram, chatId, threadLifecycle);
             result.cleaned++;
         }
@@ -419,7 +608,29 @@ export async function cleanupExpiredWorkers(db, telegram, chatId, threadLifecycl
     }
     return result;
 }
+/** Two-phase TTL teardown for a past-TTL worker still tracked in spawnedThreads.
+ *  Phase 1 (first past-TTL sweep): enter the grace window and return WITHOUT
+ *  closing the MCP socket or killing the process, so the worker can finish its
+ *  turn and deliver a final result. Phase 2 (a later sweep, once the grace
+ *  deadline passes): run the full teardown. Returns true only when Phase 2
+ *  actually tore the worker down, so the caller only counts real cleanups. */
 async function cleanupSingleWorker(thread, db, telegram, chatId, threadLifecycle) {
+    const now = Date.now();
+    const deadline = workerGraceDeadlines.get(thread.threadId);
+    if (deadline === undefined) {
+        // Phase 1: enter grace. Do NOT closeThreadSessions and do NOT killProcessTree
+        // — the MCP socket MUST stay open so the worker can still deliver its result.
+        // The poll loop surfaces the "wrap up" message to the worker via isWorkerInGrace.
+        workerGraceDeadlines.set(thread.threadId, now + WORKER_GRACE_MS);
+        log.info(`[worker-cleanup] Worker ${thread.threadId} ('${thread.name}') past TTL — entering grace (min ${Math.round(WORKER_GRACE_MS / 1000)}s) to deliver its final result. Teardown happens on a later sweep, so effective kill of a non-delivering worker is bounded by the sweep cadence (~5–10 min past TTL), not exactly ${Math.round(WORKER_GRACE_MS / 1000)}s.`);
+        return false;
+    }
+    if (now <= deadline) {
+        // Still inside grace — keep the socket open and let the worker finish.
+        return false;
+    }
+    // Phase 2: grace elapsed — full teardown (decommissionWorker clears the deadline).
     await decommissionWorker(thread, { db, telegram, chatId, threadLifecycle });
+    return true;
 }
 //# sourceMappingURL=worker-cleanup.service.js.map