fix(engine): cap auto workers by parent heap budget

packages/engine/src/services/parallelCoordinator.heap.test.ts

@@ -0,0 +1,65 @@
+import { describe, expect, it, vi } from "vitest";
+import { getHeapStatistics } from "v8";
+import { computeWorkerSizing } from "./parallelCoordinator.js";
+
+vi.mock("os", async (importOriginal) => ({
+  ...(await importOriginal<typeof import("os")>()),
+  cpus: () =>
+    Array.from({ length: 18 }, () => ({
+      model: "test",
+      speed: 3000,
+      times: { user: 0, nice: 0, sys: 0, idle: 0, irq: 0 },
+    })),
+}));
+vi.mock("./systemMemory.js", () => ({ getSystemTotalMb: () => 24576 }));
+vi.mock("v8", async (importOriginal) => {
+  const original = await importOriginal<typeof import("v8")>();
+  return { ...original, getHeapStatistics: vi.fn(original.getHeapStatistics) };
+});
+
+function withHeapLimit(mb: number): void {
+  vi.mocked(getHeapStatistics).mockReturnValueOnce({
+    ...getHeapStatistics(),
+    heap_size_limit: mb * 1024 * 1024,
+  });
+}
+
+describe("parent heap worker cap", () => {
+  it("caps the reported 18-core/24GB host at four workers with a 4GB heap", () => {
+    withHeapLimit(4096);
+    const result = computeWorkerSizing(1800);
+    expect(result).toMatchObject({
+      workers: 4,
+      heapBasedWorkers: 4,
+      boundBy: "heap",
+      exceedsHeapAdvisory: false,
+    });
+  });
+
+  it("allows one worker below the heap reserve despite the parallel floor", () => {
+    withHeapLimit(512);
+    expect(computeWorkerSizing(1800)).toMatchObject({ workers: 1, boundBy: "heap" });
+  });
+
+  it("keeps the CPU contention cap when the heap has sufficient room", () => {
+    withHeapLimit(16384);
+    expect(computeWorkerSizing(1800)).toMatchObject({ workers: 6 });
+  });
+
+  it("honors explicit workers and retains the exceeded-budget diagnostic", () => {
+    withHeapLimit(1024);
+    expect(computeWorkerSizing(1800, 6)).toMatchObject({
+      workers: 6,
+      boundBy: "explicit",
+      exceedsHeapAdvisory: true,
+    });
+  });
+
+  it("does not let configured concurrency bypass the heap budget", () => {
+    withHeapLimit(1024);
+    expect(computeWorkerSizing(1800, undefined, { concurrency: 12 })).toMatchObject({
+      workers: 1,
+      boundBy: "heap",
+    });
+  });
+});

packages/engine/src/services/parallelCoordinator.ts

@@ -141,10 +141,8 @@ const MEMORY_PER_WORKER_MB = 1536;
 const HEAP_RESERVED_MB = 1024;
 // Parent-process V8 heap consumed per worker (protocol buffers + in-flight
 // frame buffers). Derived from the field OOM: 6 workers exhausted a ~4GB
-// default heap ⇒ >~500MB/worker + base. ponytail: advisory-only until the
-// workers_heap_* telemetry added alongside this constant validates the figure
-// — enforcing a guessed budget could silently cut worker counts fleet-wide.
-// TODO(PRINFRA-341): decide enforcement after ~2 weeks of fleet soak.
+// default heap ⇒ >~500MB/worker + base. Validate this estimate against the
+// workers_heap_* fleet telemetry before rollout (PRINFRA-341).
 const HEAP_PER_WORKER_MB = 640;
 const MIN_WORKERS = 1;
 const MAX_WORKER_DIAGNOSTIC_LINES = 8;
@@ -272,6 +270,7 @@ export type WorkerSizingBound =
   | "too_few_frames"
   | "cpu"
   | "memory"
+  | "heap"
   | "frames"
   | "max_workers"
   | "min_parallel_floor"
@@ -290,17 +289,16 @@ export interface WorkerSizing {
   frameBasedWorkers: number;
   effectiveMaxWorkers: number;
   /**
-   * ADVISORY, not enforced (see HEAP_PER_WORKER_MB): how many workers the
-   * parent process's V8 heap could feed. Compare against `workers` in
-   * telemetry to validate the budget before enforcement.
+   * Auto-sizing cap: how many workers the parent process's V8 heap could
+   * feed. Explicit worker requests may exceed this budget.
    */
   heapBasedWorkers: number;
   /** V8 `heap_size_limit` for the parent process, MB. */
   heapLimitMb: number;
   totalMemoryMb: number;
   cpuCount: number;
   captureCostMultiplier: number;
-  /** true when the chosen count exceeds the advisory heap budget. */
+  /** true when an explicit worker count exceeds the heap budget. */
   exceedsHeapAdvisory: boolean;
 }
 
@@ -405,6 +403,14 @@ export function computeWorkerSizing(
     }
   }
 
+  // Apply after the two-worker parallel floor and CPU contention cap so a
+  // small parent heap can select one worker even for a long render. Chrome's
+  // RSS budget above does not account for buffers retained by the parent.
+  if (finalWorkers > heapBasedWorkers) {
+    finalWorkers = heapBasedWorkers;
+    boundBy = "heap";
+  }
+
   return finish(finalWorkers, boundBy, effectiveMaxWorkers);
 }
 

packages/producer/src/services/render/captureCost.ts

@@ -116,11 +116,8 @@ function combineCaptureCostEstimates(
  * - Auto-sized renders only (`requestedWorkers === undefined`) — the field
  *   failure was auto sizing, and an explicit `--workers N` is the operator's
  *   own call.
- * - Not enforced as a cap yet — the per-worker budget constant is derived
- *   from one field report; the `workers_heap_*` telemetry emitted with the
- *   sizing decides whether to enforce (see the TODO on HEAP_PER_WORKER_MB in
- *   @hyperframes/engine's parallelCoordinator). The message gives the
- *   operator the actionable knobs today.
+ * - Auto-sizing now applies the heap cap. Keep this defensive warning for
+ *   sizing values supplied by older callers or a future alternate policy.
  *
  * Pure so the message shape + firing condition are unit-testable with a
  * synthetic `WorkerSizing` (the real one depends on the host's heap).