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fix(onboard): recover failed GPU handoff checkpoints - #11124

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fix/11096-gpu-handoff
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fix(onboard): recover failed GPU handoff checkpoints#11124
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fix/11096-gpu-handoff

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@sandl99 sandl99 commented Sep 6, 2026

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Outcome

DGX Station Express onboarding no longer dead-ends when OpenShell applies the final sandbox start but returns nonzero before reporting Ready. NemoClaw reconciles the exact replacement through its existing bounded handoff check.

If a failed create preserves only the registry's verified-create checkpoint, NemoClaw restores the missing identity-bound recovery record. Same-name fresh onboarding and rebuild remain blocked until nemoclaw <sandbox> destroy --yes verifies cleanup.

Reason

The final GPU handoff treated a nonzero openshell sandbox start result as proof that start did not happen. OpenShell can apply the mutation and then time out while the sandbox is still provisioning, leaving an incomplete checkpoint. A later Express run could not recover when the separate recovery journal was also missing.

Related issues

Fixes #11096

Changes

  • Share one deadline across final start, readiness reconciliation, and exact Docker identity proof.
  • Reconstruct missing recovery authority only from a fully matching verified-create checkpoint.
  • Limit onboarding reconstruction to the requested sandbox so an unrelated checkpoint cannot block a different explicit name.
  • Apply that authority consistently to onboarding, destroy, and rebuild guards.
  • Add focused regression coverage and one concise recovery note to the command reference.

Verification

  • npm run validate:pr passed at f3d84ee72d5c52b462a5e9769904b9bd0601c105 against origin/main at 814772eedd4c1f2fd7a8769a33c3032b30076811.
  • Focused handoff, admission, retained-recovery, destroy, and rebuild suites: 120 tests passed.
  • Physical DGX Station GB300 Express install at c5008f3c975d02f5afba766295351a62c1510c91 completed managed Nemotron Ultra vLLM startup, direct CUDA proof, final OpenShell stop/start handoff, sandbox creation, and deployment verification.
  • The current-head GB300 Express rerun is pending.

Review notes

Recovery remains fail-closed unless the registry checkpoint, OpenShell identity, and Docker identity agree. Issue #11155 was expected Station behavior and is closed; it is not part of this fix.


Signed-off-by: San Dang sdang@nvidia.com

@sandl99 sandl99 self-assigned this Sep 6, 2026
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📝 Walkthrough

Walkthrough

The GPU handoff now uses one injected-clock deadline and reconciles nonzero OpenShell starts. Onboarding, destroy, and rebuild flows reconstruct retained recovery state from verified-create checkpoints.

Changes

Onboarding handoff and recovery

Layer / File(s) Summary
Shared GPU handoff deadline
src/lib/onboard/docker-gpu-supervisor-reconnect.ts, src/lib/onboard/docker-gpu-patch-finalize.ts, src/lib/onboard/docker-gpu-supervisor-reconnect.test.ts
The waiter accepts an absolute deadline and optional clock. Polling, runtime checks, sleeps, and replacement validation use the shared remaining budget.
Nonzero OpenShell start reconciliation
src/lib/onboard/docker-gpu-patch-finalize.test.ts
Tests cover Ready, exhausted Provisioning, exact container identity, namespace-scoped checks, and non-running replacements.
Retained recovery reconstruction
src/lib/state/onboard-session.ts, src/lib/state/onboard-session-cross-process-lock.test.ts
The session layer validates pending-create identity, normalizes resource evidence, and creates or reuses matching retained recovery records.
Recovery admission and cleanup integration
src/lib/onboard/entry-options.ts, src/lib/onboard.ts, src/lib/onboard/entry-options.test.ts, src/lib/actions/sandbox/destroy.ts, src/lib/actions/sandbox/destroy-retained-recovery-flow.test.ts, src/lib/actions/sandbox/rebuild-preflight-guards.ts, src/lib/actions/sandbox/rebuild-preflight-phase.ts, src/lib/actions/sandbox/rebuild-preflight-confirmation.test.ts, test/helpers/destroy-flow-test-harness.ts, test/onboarding/onboard-fresh-create-identity.test.ts, test/onboarding/onboard-fsm-live-slices.test.ts
Onboarding reconstructs unowned recoveries before option resolution. Destroy and rebuild preflight reconstruct recovery before selecting cleanup or rebuild authority. Tests cover safe reentry, destruction, rebuild blocking, and redaction.
Recovery guidance
docs/reference/commands.mdx
The documentation describes verified-create reconstruction requirements and fail-closed recovery handling.

Estimated code review effort: 4 (Complex) | ~45 minutes

Merge Risk: 🟡 Moderate · up to 1b069

The recovery changes should not merge until missing session identifiers cannot bypass retained-recovery admission and the renamed helper remains compatible. Behavioral tests should also prove that registry-only authority is reconstructed and mutable names cannot authorize unsafe replacement or deletion.

Sequence Diagram(s)

sequenceDiagram
  participant Onboarding
  participant OpenShell
  participant Docker
  participant SessionState
  Onboarding->>OpenShell: Start replacement with shared deadline
  OpenShell-->>Onboarding: Return result and lifecycle phase
  Onboarding->>Docker: Verify exact replacement container
  Docker-->>Onboarding: Return running state
  Onboarding->>SessionState: Reconstruct retained recovery from checkpoint
  SessionState-->>Onboarding: Return recovery authority
Loading

Suggested reviewers: apurvvkumaria, ericksoa, prekshivyas

🚥 Pre-merge checks | ✅ 4 | ❌ 1

❌ Failed checks (1 warning)

Check name Status Explanation Resolution
Docstring Coverage ⚠️ Warning Docstring coverage is 30.00% which is insufficient. The required threshold is 80.00%. Docstring coverage is scoped to functions touched by this diff. Analyzed 20 functions across 17 files. Write docstrings for the functions missing them to satisfy the coverage threshold.
✅ Passed checks (4 passed)
Check name Status Explanation
Linked Issues check ✅ Passed The changes satisfy issue #11096. They reconcile nonzero OpenShell start results within a shared deadline only when Docker and OpenShell confirm valid nonterminal state. They preserve failure behavior…
Out of Scope Changes check ✅ Passed The changes remain within the linked issue scope. Timing fixes, recovery reconstruction, onboarding guards, destroy handling, documentation, and regression tests all support GPU handoff recovery or or…
Description Check ✅ Passed Check skipped - CodeRabbit’s high-level summary is enabled.
Title check ✅ Passed The title clearly and concisely describes the primary changes: recovering failed GPU handoff checkpoints and related onboarding recovery state.
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Code Coverage Overview

Languages: TypeScript

TypeScript / code-coverage/plugin

The overall line coverage in commit f3d84ee in the fix/11096-gpu-handof... branch remains at 96%, unchanged from commit 814772e in the main branch.


Updated September 07, 2026 10:52 UTC

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Actionable comments posted: 1

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Inline comments:
In `@src/lib/onboard/docker-gpu-patch-finalize.ts`:
- Around line 273-276: Update the remaining-time calculation before
waitForOpenShellFinalHandoff so sub-second positive time is not truncated to
zero; pass milliseconds or the absolute finalHandoffDeadlineMs and ensure every
waiter operation remains bounded by that deadline. Add a regression case
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Actionable comments posted: 1

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Inline comments:
In `@src/lib/onboard/docker-gpu-supervisor-reconnect.test.ts`:
- Line 41: Add behavioral coverage for waitForOpenShellFinalHandoff that
distinguishes millisecond-based timeouts from seconds: use a subsecond or
1,500-millisecond budget with controlled elapsed time, then assert the public
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CI disposition for final candidate 7d7be4dca: 50 checks passed and 17 were skipped. The three red contexts (cli-test-shards (7), cli-tests, and checks) have one root cause: an unchanged synchronous test in src/lib/inference/serving/host-local-vllm-selection.test.ts:149 exceeded the generic 5-second test timeout under shard load. This PR does not change src/lib/inference/serving/**; the isolated file passes locally (17/17, 1.66 seconds), and the immediately preceding candidate completed all 53 checks successfully. All final-candidate managed image, direct startup, all-agent activation, and both MCP discovery checks passed. No broad rerun was requested because the checked-in retry policy does not authorize one for this signature.

@sandl99
sandl99 marked this pull request as ready for review September 6, 2026 16:51
Signed-off-by: San Dang <sdang@nvidia.com>
@sandl99 sandl99 changed the title fix(onboard): reconcile ambiguous GPU handoff start fix(onboard): recover failed GPU handoff checkpoints Sep 7, 2026
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Actionable comments posted: 1

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Inline comments:
In `@src/lib/actions/sandbox/destroy-retained-recovery-flow.test.ts`:
- Around line 89-92: Update the no-delete assertion in the destroy-retained
recovery-flow test to inspect every recorded runOpenshellSpy call and reject any
whose command arguments begin with ["sandbox", "delete", "alpha"], regardless of
whether optional arguments are absent, null, or undefined.

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Actionable comments posted: 2

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Inline comments:
In `@src/lib/actions/sandbox/rebuild-preflight-confirmation.test.ts`:
- Line 202: Update the recovery-store mock in the reconstruction test to return
an empty list initially, then expose recoveryRecord only after the
reconstruction mock runs, so the rebuild proceeds based on reconstructed state.
Preserve assertions through the public action outcome rather than adding
mock-call or private-shape assertions.
- Line 168: Update the assertion using errorSpy.mock.calls so it inspects every
argument from every captured console.error call, not only call[0], and fails if
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Actionable comments posted: 2

🧹 Nitpick comments (1)
test/onboarding/onboard-fsm-live-slices.test.ts (1)

499-509: 🗄️ Data Integrity & Integration | 🔵 Trivial | ⚡ Quick win

Assert recovery behavior at the public boundary.

This test stubs readOptions and resolveEntryOptions, then asserts internal call markers. A no-op recovery resolver could pass by emitting "recovery-pass" without reconstructing recovery authority. A valid implementation refactor could also fail because the test requires this internal call order.

Seed the registry-only pending-create state and assert the observable onboarding result, such as retained recovery authority or refusal of unsafe replacement. Keep call-order checks only as secondary diagnostics.

As per path instructions, tests under **/*.test.{ts,js,mts,mjs,cts,cjs} must favor behavioral confidence over implementation lock-in.

Also applies to: 650-652

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In `@test/onboarding/onboard-fsm-live-slices.test.ts` around lines 499 - 509,
Update the onboarding FSM test around onboardEntryOptions.readOptions and
resolveEntryOptions to seed registry-only pending-create state and assert the
public onboarding outcome, such as preserved recovery authority or rejection of
unsafe replacement. Demote internal call markers and ordering to optional
secondary diagnostics so valid resolver refactors remain supported.

Source: Path instructions

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Inline comments:
In `@src/lib/onboard/entry-options.ts`:
- Line 269: Retain a compatibility export for the renamed
resolveDefaultRunEntryOptionsFromState helper by exposing the old symbol as a
wrapper or alias that delegates to readOptions, while preserving readOptions as
the primary implementation.
- Line 131: Update reconstructUnownedPendingCreateRecoveries so the ownership
exception only applies when a defined reservationSessionId matches
persistedSession?.sessionId; do not treat two undefined values as equal. Ensure
unmatched pending-create entries retain their recovery records so readOptions
receives them and enforces recovery admission.

---

Nitpick comments:
In `@test/onboarding/onboard-fsm-live-slices.test.ts`:
- Around line 499-509: Update the onboarding FSM test around
onboardEntryOptions.readOptions and resolveEntryOptions to seed registry-only
pending-create state and assert the public onboarding outcome, such as preserved
recovery authority or rejection of unsafe replacement. Demote internal call
markers and ordering to optional secondary diagnostics so valid resolver
refactors remain supported.

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Reviewed at 3152c29 against 814772e. No blocker. The nonzero-start reconciliation matches #11096: the waiter runs within the same deadline and keeps polling only while Docker proves the exact replacement is the sole running labeled container and the phase is nonterminal. Reconstruction is fail-closed, lock-guarded, and idempotent.

  1. reconstructUnownedPendingCreateRecoveries has no case for the literal DGX Station Express GPU handoff fails before the configured readiness deadline #11096 path: plain rerun (no --fresh, no --resume), session status failed, matching reservationSessionId. Unit and integration cases both use fresh: true. One more it.each row.

  2. The "independent recovery authority conflicts with the verified create checkpoint" branch in reconstructRetainedSandboxRecoveryFromPendingCreate has no test; only the entry-vs-checkpoint mismatch does.

  3. resolveEntryOptions reconstructs every registry entry, so a mismatched checkpoint on sandbox A also stops onboard --name B, and destroy A throws before doing anything. Is the mismatch reachable without hand-editing the registry? If not, a one-line note settles it. If yes, catch per entry and continue for other names.

  4. process-recovery.ts checks replacementRestarted === false before finalHandoffAcknowledged === false. With replacementRestarted = start || acknowledged, false now means the start returned nonzero and reconciliation did not converge, but the message still says "could not start" and drops lastSandboxPhase. Swap the order or include the phase.

  5. readOptions duplicates resolveDefaultRunEntryOptionsFromState. The README rule cited is about moving files, not renaming helpers. Call the original name from onboard.ts and the FSM test.

  6. A checkpoint without createAttemptNonce returns null silently, so checkpoints written before fix(onboard): preserve retained sandbox authority #10510 stay in the same dead end with no message. Print why reconstruction was skipped.

  7. Nit: Math.max(1, finalHandoffTimeoutSecs * 1000) has no finite guard, unlike the waiter. Theoretical today since callers use envInt.

Merge readiness: the checks context is green from the gate-false run (every job skipped except checks) while run 34112172914 is still on cli-test-shards. GB300 evidence at c5008f3 still covers the handoff code; no GPU handoff file changed after that commit. #11106 and #10867 touch the same files; a three-way merge dry run shows no textual conflicts.

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@sandl99
sandl99 merged commit 1c60315 into main Sep 7, 2026
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sandl99 deleted the fix/11096-gpu-handoff branch September 7, 2026 11:04
cv pushed a commit that referenced this pull request Sep 7, 2026
<!-- markdownlint-disable MD041 -->
## Outcome

Restores the two paths failing in main CI: registry-only fresh
onboarding reconstructs retained sandbox identity before gateway
preflight, and Hermes legacy-layout startup accepts the trusted
pre-migration directory posture.

## Reason

Main CI run 34114747276 repeated both failures across attempts. The
onboarding coverage added by #11124 kept its verified create checkpoint
only in memory, while the Hermes hardening from #11110 rejected the safe
legacy 0750 directory mode before startup could repair it.

## Changes

- Capture the verified pending-create entry when the generated fixture
persists it and pass that entry only to the registry-only recovery
child.
- Include the gateway port in the shared verified-create reservation
fixture so the durable pending entry matches the production registry
authority.
- Accept sandbox-owned 0750 as a trusted transitional Hermes root
posture; the existing startup path remains responsible for repairing it
to the canonical mode.
- Reject the adjacent 0755 posture and retain the exact ownership,
group, and mode boundary.
- Refresh the Dockerfile integrity pin for the changed security
validator.

## Verification

- Contributor validation: npm run validate:pr passed for
e080d1f.
- Focused tests: the Hermes 0750 acceptance and 0755 rejection tests
passed; the validator digest-binding probe passed; the Hermes startup
mode-repair test passed; the onboarding recovery unit suite passed
40/40; npm run build:cli passed.
- Repository checks: test-title, growth-guardrail, formatting, lint,
type-check, hadolint, and secret-scan checks passed.
- The Linux-only Docker-backed onboarding regression case is delegated
to PR CI because this macOS checkout skips that lane by design.
- Secrets review: the diff contains no secrets, API keys, or
credentials.

---
Signed-off-by: San Dang <sdang@nvidia.com>

---------

Signed-off-by: San Dang <sdang@nvidia.com>
@wscurran wscurran added the bug-fix PR fixes a bug or regression label Sep 8, 2026
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DGX Station Express GPU handoff fails before the configured readiness deadline

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