fix(startup): thread-exhaustion resilience — cap workers, never panic

Port of upstream grok-build 0.2.113/0.2.114 fixes, extended to Kigi's
startup order.

- kigi-tty-utils runtime module: worker-cap policy (8 max) — tokio's
  per-core default pins 100+ thread slots on many-core shared hosts
  against RLIMIT_NPROC / pids.max, and later spawns die with EAGAIN.
- kigi-bin builds the main runtime with capped workers and reports an
  out-of-threads host with a diagnostic + exit(1) instead of a panic.
- The pre-runtime optimization threads (HTTP warmup, early model
  prefetch) spawn recoverably and degrade — their panic would have
  preempted the runtime's own diagnostic.
- The per-session actor thread and its runtime report spawn/build
  failure through the existing acp::Error / AgentBuildError boundaries
  (new RuntimeBuild variant) instead of panicking the agent host.
- fsnotify's watcher thread spawn maps into FsNotifyError::WatcherStart
  so callers degrade instead of crashing.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01KSy9S31pZNWXtRZNVJ1sDf
This commit is contained in:
ZacharyZhang-NYandClaude Fable 5 committed 2026-08-27 11:28:17 -04:00
1 parent bf93091416
commit 97de661554
8 files changed
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@@ -1221,10 +1221,26 @@ fn main() {
"Found crashed sessions from a previous run"
);
}
let runtime = tokio::runtime::Builder::new_multi_thread()
// Capped workers: tokio's per-core default pins 100+ thread slots on
// many-core shared hosts and later spawns die with EAGAIN.
let runtime = match tokio::runtime::Builder::new_multi_thread()
.worker_threads(kigi_tty_utils::runtime::capped_worker_threads().get())
.enable_all()
.build()
.unwrap_or_else(|e| panic!("failed to start tokio runtime: {e}"));
{
Ok(runtime) => runtime,
Err(e) => {
// A host out of threads (RLIMIT_NPROC / pids.max) is an
// environment problem, not a bug — report it, don't panic.
kigi_tty_utils::restore_native_stderr();
eprintln!("Error: failed to start the async runtime: {e}");
eprintln!(
"The host may be out of threads (RLIMIT_NPROC or the cgroup pids ceiling); \
close other processes or raise the limit, then retry."
);
std::process::exit(1);
}
};
let result = run_and_shutdown(runtime, async_main(), RUNTIME_SHUTDOWN_GRACE);
kigi_log::debug_log::flush();
if let Err(e) = result {