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

crates/codegen/kigi-shell/src/agent/models.rs

@@ -1938,7 +1938,7 @@ fn resolve_prefetch_env(kimi_code_config: Option<KimiCodeConfig>) -> Option<Pref
 /// credentials from disk.
 pub fn start_early_prefetch_with_auth(auth: Option<KimiAuth>) -> Option<EarlyPrefetchHandle> {
     let env = resolve_prefetch_env_with_auth(auth)?;
-    Some(spawn_prefetch_thread(env))
+    spawn_prefetch_thread(env)
 }
 
 /// Start the model-catalog prefetch on a background thread.
@@ -1949,11 +1949,16 @@ pub fn start_early_prefetch(
     kimi_code_config: Option<KimiCodeConfig>,
 ) -> Option<EarlyPrefetchHandle> {
     let env = resolve_prefetch_env(kimi_code_config)?;
-    Some(spawn_prefetch_thread(env))
+    spawn_prefetch_thread(env)
 }
 
-fn spawn_prefetch_thread(env: PrefetchEnv) -> EarlyPrefetchHandle {
-    std::thread::spawn(move || {
+/// `None` when the OS refuses a thread: the prefetch is an optimization and
+/// runs before the runtime builds, so a spawn panic here would preempt the
+/// runtime's own out-of-threads diagnostic.
+fn spawn_prefetch_thread(env: PrefetchEnv) -> Option<EarlyPrefetchHandle> {
+    let spawned = std::thread::Builder::new()
+        .name("early-prefetch".into())
+        .spawn(move || {
         let mut timer = crate::instrumentation_timer!("startup.early_prefetch");
         let proxy_endpoint = env.endpoints.proxy_url();
         timer.with_field("endpoint", proxy_endpoint.as_str());
@@ -1993,7 +1998,14 @@ fn spawn_prefetch_thread(env: PrefetchEnv) -> EarlyPrefetchHandle {
         }
 
         EarlyPrefetchResult { models }
-    })
+    });
+    match spawned {
+        Ok(handle) => Some(handle),
+        Err(e) => {
+            tracing::error!(error = %e, "early prefetch thread spawn failed; skipping prefetch");
+            None
+        }
+    }
 }
 
 /// Map a model id (catalog key or routing slug) to its catalog key.

crates/codegen/kigi-shell/src/agent/mvp_agent/mod.rs

@@ -726,10 +726,18 @@ pub struct MvpAgent {
 /// sampling client is discarded, but the TLS root certificates it loads
 /// are cached at the process level by `rustls-native-certs`.
 pub fn warm_async_http_client() {
-    std::thread::spawn(|| {
-        let _timer = crate::instrumentation_timer!("startup.async_http_warmup");
-        let _ = crate::http::shared_client();
-    });
+    // Recoverable spawn: the warmup is an optimization that runs before the
+    // runtime builds — an out-of-threads host must reach the runtime's own
+    // diagnostic, not panic here.
+    let spawned = std::thread::Builder::new()
+        .name("http-warmup".into())
+        .spawn(|| {
+            let _timer = crate::instrumentation_timer!("startup.async_http_warmup");
+            let _ = crate::http::shared_client();
+        });
+    if let Err(e) = spawned {
+        tracing::warn!(error = %e, "async HTTP warmup thread spawn failed; first request warms instead");
+    }
 }
 pub(crate) fn resolve_required_agent_type(
     model_agent_type: Option<&str>,