Files
PaperClipAI/server
DottaandClaude Opus 5.5 0c9962a9bc fix(plugins): replace a retired worker with a fresh process (#19245)
## Thinking Path

> - Paperclip is the open source app people use to manage AI agents for
work
> - Sandbox providers such as Daytona run as plugin workers that the
host manages in `server/src/services/plugin-worker-manager.ts`
> - The host retires a worker when it cannot prove that a login
pseudo-terminal or a duplex channel route is gone (fail closed)
> - Retirement used `killProcess()`, which marks a deliberate stop, so
the handle stayed `stopped` and no restart followed
> - Every later call then failed with `Cannot call "<method>" — worker
for "<id>" is stopped` until the server process restarted
> - This pull request makes a retirement replace the worker with a fresh
process through the existing backoff timer, with a bound on repeated
retirements
> - The benefit is that one unconfirmed close no longer makes a sandbox
provider unavailable for the whole server

## Linked Issues or Issue Description

Refs #19150

**What happened?**
A Daytona plugin worker was retired after an unacknowledged duplex
close. After that, every run that used the Daytona environment failed
setup with `Cannot call "environmentExecute" — worker for <plugin> is
stopped`. 15 runs failed in about 12 minutes. The plugin stayed
unavailable until the server restarted. #19150 removed the specific
trigger. It keeps fail-closed retirement for close replies that the host
cannot confirm, so the same outage can still occur.

**Expected behavior**
The retired process, its routes, and its tombstones are never reused.
The plugin comes back on a fresh process after a short, bounded backoff.
A deliberate stop (plugin disable, upgrade, shutdown) stays stopped.

**Steps to reproduce**
1. Start a plugin worker and open a duplex channel whose close
acknowledgement is wrong or missing.
2. Close the channel. The host retires the worker.
3. Call any worker method. Before this change, the call fails with `is
stopped` forever.

## What Changed

- Add `retireWorkerProcess()`. It kills the process but does not mark a
deliberate stop. The three fail-closed retirement paths use it instead
of `killProcess()`.
- In the exit handler, a retired exit settles every route as before,
then counts the retirement and schedules a fresh process through the
existing backoff timer (`crashed` → `backoff` → `running`). It emits the
existing `crash` event with `willRestart`.
- A deliberate stop wins. If `stop()` runs before the exit, the exit
ends `stopped`. If `stop()` runs during backoff, it cancels the restart.
- Bound repeated retirements: at most 5 retirements in the 10-minute
crash window. A successful restart does not reset this count (it does
reset the crash count), so a worker that starts cleanly and is retired
again cannot loop forever. After the bound, the worker stays `crashed`.
- `scheduleRestart()` / `computeBackoffMs()` take the attempt number, so
the crash path and the retirement path each use their own counter.
- Add an optional `crashRecovery` start option (`minBackoffMs`,
`maxConsecutiveRetirements`) so tests can use short waits.
- Update the Daytona worker close test: a stalled close now shows
`backoff`, then a fresh `running` process with a new pid.

## Verification

- Red before the fix: the three new tests in
`server/src/__tests__/plugin-worker-manager-duplex.test.ts` (`plugin
worker replacement after a fail-closed retirement`) failed with
`expected 'stopped' to be 'running'` / `'backoff'`.
- Green after the fix. The tests prove:
- the retired route and a sibling route on the same worker both settle
with `{ exitCode: null }`;
- the fresh process has a new pid, a write to a retired route does not
revive it, and a new route on the fresh process echoes data;
  - `stop()` during backoff stays `stopped` with no process;
- with `maxConsecutiveRetirements: 2`, the third retirement leaves the
worker `crashed` and `call()` rejects.
- The real Daytona plugin worker test
(`plugin-worker-manager-daytona-close.test.ts`, `stalled-close`) now
shows the replacement with the actual provider bundle. The closed lease
still rejects on the fresh process.
- `cd server && npx vitest run src/__tests__/plugin
src/__tests__/managed-plugin src/services/plugin` → 48 files, 649 tests
pass. The new tests passed 5 runs in a row.
- `npx tsc --noEmit -p server` shows no errors in the changed files.
- Not run: a live staging run. This PR does not deploy.

## Risks

- A plugin that keeps causing retirements now restarts up to 5 times in
10 minutes (1s, 2s, 4s, 8s, 16s backoff) instead of staying dead. After
that, it stays `crashed`, as a crash loop does now.
- A retirement now emits `plugin.worker.crashed`, so host-service
cleanup runs for the plugin, the same as for a crash. A restart emits
`plugin.worker.restarted`. A retirement also counts in `totalCrashes`,
so idle sleep treats the worker as it treats a crashed worker.
- A call made during backoff fails with `is backoff` rather than `is
stopped`. The outage is bounded to the backoff, not to a server restart.

## Model Used

- Claude Opus 5.5 (`claude-opus-5-5`) in Claude Code, with tool use
(shell, file edit, test runs).

## Checklist

- [x] I have included a thinking path that traces from project context
to this change
- [x] I have specified the model used (with version and capability
details)
- [x] I have checked ROADMAP.md and confirmed this PR does not duplicate
planned core work
- [x] I have searched GitHub for duplicate or related PRs and linked
them above
- [x] I have either (a) linked existing issues with `Fixes: #` / `Closes
#` / `Refs #` OR (b) described the issue in-PR following the relevant
issue template
- [x] I have not referenced internal/instance-local Paperclip issues or
links (only public GitHub `#NNN` / `github.com/paperclipai/paperclip`
URLs)
- [x] My branch name describes the change (e.g. `docs/...`, `fix/...`)
and contains no internal Paperclip ticket id or instance-derived details
- [x] I have run tests locally and they pass
- [x] I have added or updated tests where applicable
- [x] I have updated relevant documentation to reflect my changes
- [x] I have considered and documented any risks above
- [ ] All Paperclip CI gates are green
- [ ] Greptile is 5/5 with no open P2s, recommendations, or follow-ups
- [x] I will address all Greptile and reviewer comments before
requesting merge

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-authored-by: Claude Opus 5.5 <noreply@anthropic.com>
2026-11-05 08:37:16 -06:00
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