From 742c9baabcb9a774c9c05f5df78ed9e869049cf6 Mon Sep 17 00:00:00 2001
From: Andy Lee <andylizf@outlook.com>
Date: Fri, 8 Aug 2025 22:48:40 -0700
Subject: [PATCH] fix: increase outer timeout to 360s to respect pytest's 300s
 timeout

The outer shell timeout must be larger than pytest's internal timeout (300s)
to allow pytest to handle its own timeout gracefully and perform cleanup.

Changes:
- Increased outer timeout from 180s to 360s (300s + 60s buffer)
- Made timeouts configurable via environment variables
- Added clear documentation about timeout hierarchy
- Display timeout configuration at runtime

Timeout hierarchy:
1. Individual test: 20s (markers)
2. Pytest session: 300s (pyproject.toml)
3. Outer shell: 360s (for cleanup)
4. GitHub Actions: 6 hours (default)

This prevents the outer timeout from killing pytest before it can finish
its own timeout handling, which was likely causing the hanging issues.
---
 .github/workflows/build-reusable.yml | 27 ++++++++++++++++++++++++---
 1 file changed, 24 insertions(+), 3 deletions(-)

diff --git a/.github/workflows/build-reusable.yml b/.github/workflows/build-reusable.yml
index 99781e5..45d6025 100644
--- a/.github/workflows/build-reusable.yml
+++ b/.github/workflows/build-reusable.yml
@@ -265,6 +265,11 @@ jobs:
           limit-access-to-actor: true
 
       - name: Run tests with pytest
+        # Timeout hierarchy:
+        # 1. Individual test timeout: 20s (see pyproject.toml markers)
+        # 2. Pytest session timeout: 300s (see pyproject.toml [tool.pytest.ini_options])
+        # 3. Outer shell timeout: 360s (300s + 60s buffer for cleanup)
+        # 4. GitHub Actions job timeout: 6 hours (default)
         env:
           CI: true  # Mark as CI environment to skip memory-intensive tests
           OPENAI_API_KEY: ${{ secrets.OPENAI_API_KEY }}
@@ -349,8 +354,24 @@ jobs:
             echo "🔌 Pre-test network state:"
             ss -ltn 2>/dev/null | grep -E "555[0-9]|556[0-9]" || echo "No embedding server ports open"
 
-            echo "🏃 Running pytest with 180s timeout..."
-            timeout --preserve-status --signal=INT --kill-after=10 180 bash -c '
+            # Set timeouts - outer must be larger than pytest's internal timeout
+            # IMPORTANT: Keep PYTEST_TIMEOUT_SEC in sync with pyproject.toml [tool.pytest.ini_options] timeout
+            PYTEST_TIMEOUT_SEC=${PYTEST_TIMEOUT_SEC:-300}  # Default 300s, matches pyproject.toml
+            BUFFER_SEC=${TIMEOUT_BUFFER_SEC:-60}  # Buffer for cleanup after pytest timeout
+            OUTER_TIMEOUT_SEC=${OUTER_TIMEOUT_SEC:-$((PYTEST_TIMEOUT_SEC + BUFFER_SEC))}
+
+            echo "⏰ Timeout configuration:"
+            echo "   - Pytest internal timeout: ${PYTEST_TIMEOUT_SEC}s (from pyproject.toml)"
+            echo "   - Cleanup buffer: ${BUFFER_SEC}s"
+            echo "   - Outer shell timeout: ${OUTER_TIMEOUT_SEC}s (${PYTEST_TIMEOUT_SEC}s + ${BUFFER_SEC}s buffer)"
+            echo "   - This ensures pytest can complete its own timeout handling and cleanup"
+
+            echo "🏃 Running pytest with ${OUTER_TIMEOUT_SEC}s outer timeout..."
+
+            # Export for inner shell
+            export PYTEST_TIMEOUT_SEC OUTER_TIMEOUT_SEC BUFFER_SEC
+
+            timeout --preserve-status --signal=INT --kill-after=10 ${OUTER_TIMEOUT_SEC} bash -c '
               echo "⏱️ Pytest starting at: $(date)"
               echo "Running command: pytest tests/ -vv --maxfail=3 --tb=short --capture=no"
 
@@ -382,7 +403,7 @@ jobs:
             echo "🔚 Timeout command exited with code: $EXIT_CODE"
 
                         if [ $EXIT_CODE -eq 124 ]; then
-              echo "⚠️ TIMEOUT TRIGGERED - Tests took more than 180 seconds!"
+              echo "⚠️ TIMEOUT TRIGGERED - Tests took more than ${OUTER_TIMEOUT_SEC} seconds!"
               echo "📸 Capturing full diagnostics..."
               diag