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Tom Boucher f6257f3745 ci(#2952): shard the full test lane instead of widening its cap (#2960) 
* ci(#2952): budget CI job timeouts by headroom over measured cost

`origin/next` was red. The only failing check was `Required tests`, and its
sole cause was `test (ubuntu-latest, 24)` reported `cancelled` — GitHub's
conclusion for a job that exceeds its `timeout-minutes`, not a button press.

That job's `ubuntu-latest / 24` entry is the only `scope: full` matrix entry:
it runs the whole unit suite under c8 coverage, then the scripts/ coverage
floor, integration, security, install and slow, serially on one runner. On
next@5a0a9f097 it ran 15m16s against `timeout-minutes: 15` and was axed 23s
into `npm run test:slow`. Projected to a completed slow step (27s on the last
green run) the lane costs ~15m20s.

Confirmed hypothesis: the budget, not the suite. The lane had been riding the
ceiling all day — 12m03s, 11m34s, 11m50s, 14m25s, 14m51s — and crossed on
three of the last four full-lane runs (d2d2f7c08, 07603df8f, 5a0a9f097). There
is no pathological test: the unit run is cost-first bin-packed into 12 chunks,
chunk 1 is gated by run-tests-harness.test.cjs at 169s (expensive by design —
it spawns real harness subprocesses, one of which exercises the per-chunk
timeout), and the remaining chunks are 32-94s. 769s is the honest cost of 689
files under c8. Re-running could not have helped; the work exceeded the budget.

Review of the first cut surfaced the same defect one runner away: `full test
(windows-latest, 22, shard 3/3)` reached 18m59s against its own 20-minute cap
on 05b170e44 (94%) and 18m14s on 81eeb8a53 (91%). That lane has already blown
its cap twice (#1051, #1212). Fixed here rather than deferred.

The first cut also asserted `test >= test-full`, which is unsound — those two
budgets are dominated by different platforms, so their ordering carries no
meaning. Replaced with the invariant that actually generalises: every lane is
held to a headroom FACTOR over its own measured cost. `test` 15 -> 25 (1.5x of
16m), `test-full` 20 -> 30 (1.5x of 19m), `test-inert` unchanged at 15.

tests/ci-test-job-timeout-budget.test.cjs locks that rule. No unit test can
prove a lane still FITS its budget — only a real run measures that — but a
budget can no longer be lowered back beneath what its lane is known to need,
and a lane that gets slower must be re-measured rather than excused.

Separately: the earlier `failure` at 05b170e44 was an unrelated, already-fixed
CONTEXT-INDEX.json drift (07603df8f re-synced it; lint-tests is green at HEAD).
07603df8f's own run hit this same timeout, which is why it never reported green.

Refs #869, #1051, #1212

* ci(#2952): shard the full test lane instead of widening its cap

The `scope: full` lane was the only unsharded lane in this file. It ran the
entire unit suite under c8 on one runner, grew past a 15-minute cap, and
reddened `next`. Raising the cap bought room; it did not change the shape, and
the same lane would have walked back into the ceiling. Shard it, the way #1212
answered this for the Windows lane.

Balance comes from measurement, not file counts. scripts/run-tests.cjs already
partitions by measured per-file duration using LPT (#2472); the table it reads
was 10 days stale — 638 of 695 files timed, 64 missing, including the whole
context-predicates group. Regenerated from a verified matrix run: 700 files, 0
missing. On that table the 685-file unit suite splits 19.37m / 19.37m / 19.37m
— 0.0% spread — and the split is a total, disjoint cover with 0 files dropped.
Completeness, disjointness, balance and determinism of the partition itself are
already pinned against selectShard in run-tests-harness.test.cjs, including a
fast-check property, so this change does not restate them.

Sharding a COVERAGE run is the part that needs care. A per-shard percentage is
meaningless — shard 2 never executes shard 1's files, so those read 0% — and
leaving the gate on the shards would have quietly measured a third of the tree.
Each shard now renders no report and only leaves raw V8 dumps; a new
`coverage-gate` job merges all three into one coverage/tmp and runs the gate
there. c8's default temp directory is where the download lands, so the ≥70%
lines / ≥60% branches gate and the ≥55% scripts floor run unmodified against
merged data.

Both surfaces call the same npm scripts rather than inlining c8 into YAML, so
the include/exclude globs and both thresholds stay defined once in package.json.
The workflow holding its own copy is the divergence this repo has a rule
against, and the new test cross-checks package.json so an inline reintroduction
fails rather than drifts.

tests/ci-full-lane-sharding.test.cjs covers the two ways this stays GREEN while
being wrong: an incomplete shard set (declare 1/3 and 2/3, never 3/3, and a
third of the suite silently stops running) and a coverage gate that stops being
required. required-tests now depends on coverage-gate and fails on it, while
still tolerating `skipped` so docs-only PRs are not blocked.

`timeout-minutes: 25` on the lane is deliberately left alone. The budget test
requires a real measurement before a lane's declared cost changes, and the
sharded cost is not measured until this PR's own CI run.

Refs #1212, #2472

* ci(#2952): tighten the sharded lane's budget to its measured cost

The sharding commit deliberately left `timeout-minutes: 25` alone, because
tests/ci-test-job-timeout-budget.test.cjs requires a real measurement before a
lane's declared cost changes and the sharded cost did not exist yet.

It exists now. Run 30677442953: shard 1/3 7m12s, 2/3 4m32s, 3/3 3m59s, and
coverage-gate 1m20s. Shard 1 is the long pole because the unsharded aux suites
ride along on it, which is deliberate — they total ~1m35s and sharding them
would cost more than it saves.

So the lane's budget is 15 against a slowest measured shard of 8 minutes
(~1.9x), and coverage-gate joins LANE_COSTS at 2 minutes. 15 is the same number
the lane blew before sharding; the work behind it is now a third the size.

Merged coverage was checked against the pre-shard single-runner baseline rather
than assumed from a green check: 94.36 stmts / 96.3 funcs / 94.36 lines
identical, branches 84.22 vs 84.21 — one branch across two different trees,
noise rather than a regression.

---------

Co-authored-by: sim <sim@local>
2026-07-31 22:16:26 -04:00

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