fix: enforce codex turn hard timeout

src/backend/codex-stdio.ts

@@ -460,7 +460,8 @@ async function runCodexStdioTurnWithSession(options: CodexStdioTurnOptions, sess
   const suppressedNotifications = createSuppressedNotificationSummary();
   let waitingFor = "codex-app-server";
   let lastNotificationMethod: string | null = null;
-  let lastActivityAt = Date.now();
+  const turnStartedAt = Date.now();
+  let lastActivityAt = turnStartedAt;
   let lastToolCall: JsonRecord | null = null;
   let missingTerminalAfterToolReported = false;
   let threadId: string | undefined = options.threadId;
@@ -530,12 +531,44 @@ async function runCodexStdioTurnWithSession(options: CodexStdioTurnOptions, sess
     terminalResolve();
   };
   options.abortSignal?.addEventListener("abort", abortTurn, { once: true });
-  const turnIdleTimeoutMs = positiveTimeout(options.timeoutMs);
+  const turnHardTimeoutMs = positiveTimeout(options.timeoutMs);
+  const turnIdleTimeoutMs = turnHardTimeoutMs;
   const idleWarningMs = codexIdleWarningMs(env, turnIdleTimeoutMs);
   const missingTerminalAfterToolTimeoutMs = codexMissingTerminalAfterToolTimeoutMs(env, turnIdleTimeoutMs);
+  let hardTimeout: NodeJS.Timeout | null = null;
   let idleTimeout: NodeJS.Timeout | null = null;
   let idleWarningTimeout: NodeJS.Timeout | null = null;
   let missingTerminalAfterToolTimeout: NodeJS.Timeout | null = null;
+  const turnHardTimeoutAttrs = (): JsonRecord => ({
+    waitingFor,
+    elapsedMs: Math.max(0, Date.now() - turnStartedAt),
+    idleMs: Math.max(0, Date.now() - lastActivityAt),
+    timeoutMs: turnHardTimeoutMs,
+    lastNotificationMethod,
+    threadId: threadId ?? null,
+    turnId: turnId ?? null,
+    terminalStatus: terminal?.status ?? null,
+    retryable: false,
+    retryAttempt: null,
+    retryMaxAttempts: 0,
+    retryExhausted: true,
+    lastToolCall,
+  });
+  const failTurnHardTimeout = (): void => {
+    if (terminal) return;
+    const elapsedMs = Math.max(0, Date.now() - turnStartedAt);
+    terminal = { status: "failed", failureKind: "backend-timeout", message: `codex stdio turn hard timed out after ${turnHardTimeoutMs}ms total budget` };
+    const attrs = { ...turnHardTimeoutAttrs(), elapsedMs, terminalStatus: terminal.status, failureKind: terminal.failureKind };
+    emitEvent({ type: "error", payload: { failureKind: terminal.failureKind, message: terminal.message, phase: "turn:hard-timeout", timeoutMs: turnHardTimeoutMs, elapsedMs, idleMs: Math.max(0, Date.now() - lastActivityAt), waitingFor, lastNotificationMethod, threadId: threadId ?? null, turnId: turnId ?? null, retryable: false, retryAttempt: null, retryMaxAttempts: 0, retryExhausted: true, lastToolCall } });
+    emitCodexOtelSpan("codex_stdio.turn_hard_timeout", options, env, attrs, { status: "error", error: terminal.message });
+    beginInterruptAndStop("turn hard timeout", "turn:hard-timeout");
+    terminalResolve();
+  };
+  const scheduleTurnHardTimeout = (): void => {
+    if (hardTimeout) clearTimeout(hardTimeout);
+    hardTimeout = setTimeout(failTurnHardTimeout, turnHardTimeoutMs);
+    hardTimeout.unref?.();
+  };
   const missingTerminalAfterToolAttrs = (): JsonRecord => ({
     waitingFor,
     idleMs: Math.max(0, Date.now() - lastActivityAt),
@@ -603,6 +636,8 @@ async function runCodexStdioTurnWithSession(options: CodexStdioTurnOptions, sess
     idleTimeout.unref?.();
   };
   const stopTurnIdleTimeout = (): void => {
+    if (hardTimeout) clearTimeout(hardTimeout);
+    hardTimeout = null;
     if (!idleTimeout) return;
     clearTimeout(idleTimeout);
     idleTimeout = null;
@@ -610,6 +645,7 @@ async function runCodexStdioTurnWithSession(options: CodexStdioTurnOptions, sess
     idleWarningTimeout = null;
     clearMissingTerminalAfterToolTimeout();
   };
+  scheduleTurnHardTimeout();
   refreshTurnActivity();
   const stopNotifications = session.addNotificationHandler((message) => {
     refreshTurnActivity();