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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@@ -971,7 +971,7 @@ pub(crate) fn start_with_timeout(
let progress_for_thread = progress.clone();
let thread = std::thread::spawn(move || {
let watcher_loop = move || {
let update_stage = |stage: &'static str| {
if let Ok(mut p) = progress_for_thread.lock() {
p.set_stage(stage);
@@ -1351,7 +1351,13 @@ pub(crate) fn start_with_timeout(
let _ = ready_tx.send(Err(Box::new(e)));
}
}
});
};
// Recoverable spawn: a host out of threads must surface as an error the
// caller can degrade on, not a `std::thread::spawn` panic.
let thread = std::thread::Builder::new()
.name("fsnotify-watcher".into())
.spawn(watcher_loop)
.map_err(|e| crate::FsNotifyError::WatcherStart(Box::new(e)))?;
// Wait for watcher to be ready (with timeout)
if let Ok(mut p) = progress.lock() {