fix: increase timeouts for slow systems

Phase 2 of worker lifecycle fix - applying timeout increases:

- hook-constants.ts: DEFAULT 120s→300s, HEALTH_CHECK 1s→30s, RETRIES 15→300
- worker-service.ts: context init 30s→300s, MCP 15s→300s, PowerShell 5s→60s
- BranchManager.ts: GIT_COMMAND 30s→300s, NPM_INSTALL 120s→600s
- hooks.json: worker start/restart 30s→180s, hook execution 120s→300s

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

plugin/hooks/hooks.json

@@ -8,7 +8,7 @@
           {
             "type": "command",
             "command": "bun \"${CLAUDE_PLUGIN_ROOT}/scripts/worker-cli.js\" restart",
-            "timeout": 30
+            "timeout": 180
           },
           {
             "type": "command",
@@ -29,12 +29,12 @@
           {
             "type": "command",
             "command": "bun \"${CLAUDE_PLUGIN_ROOT}/scripts/worker-cli.js\" start",
-            "timeout": 30
+            "timeout": 180
           },
           {
             "type": "command",
             "command": "node \"${CLAUDE_PLUGIN_ROOT}/scripts/new-hook.js\"",
-            "timeout": 120
+            "timeout": 300
           }
         ]
       }
@@ -46,12 +46,12 @@
           {
             "type": "command",
             "command": "bun \"${CLAUDE_PLUGIN_ROOT}/scripts/worker-cli.js\" start",
-            "timeout": 30
+            "timeout": 180
           },
           {
             "type": "command",
             "command": "node \"${CLAUDE_PLUGIN_ROOT}/scripts/save-hook.js\"",
-            "timeout": 120
+            "timeout": 300
           }
         ]
       }
@@ -62,12 +62,12 @@
           {
             "type": "command",
             "command": "bun \"${CLAUDE_PLUGIN_ROOT}/scripts/worker-cli.js\" start",
-            "timeout": 30
+            "timeout": 180
           },
           {
             "type": "command",
             "command": "node \"${CLAUDE_PLUGIN_ROOT}/scripts/summary-hook.js\"",
-            "timeout": 120
+            "timeout": 300
           }
         ]
       }

src/services/worker-service.ts

@@ -266,7 +266,7 @@ export class WorkerService {
     this.app.get('/api/context/inject', async (req, res, next) => {
       try {
         // Wait for initialization to complete (with timeout)
-        const timeoutMs = 30000; // 30 second timeout
+        const timeoutMs = 300000; // 5 minute timeout for slow systems
         const timeoutPromise = new Promise((_, reject) => 
           setTimeout(() => reject(new Error('Initialization timeout')), timeoutMs)
         );
@@ -326,7 +326,7 @@ export class WorkerService {
     if (isWindows) {
       // Windows: Use PowerShell Get-CimInstance to find chroma-mcp processes
       const cmd = `powershell -Command "Get-CimInstance Win32_Process | Where-Object { $_.Name -like '*python*' -and $_.CommandLine -like '*chroma-mcp*' } | Select-Object -ExpandProperty ProcessId"`;
-      const { stdout } = await execAsync(cmd, { timeout: 5000 });
+      const { stdout } = await execAsync(cmd, { timeout: 60000 });
 
       if (!stdout.trim()) {
         logger.debug('SYSTEM', 'No orphaned chroma-mcp processes found (Windows)');
@@ -381,7 +381,7 @@ export class WorkerService {
           logger.warn('SYSTEM', 'Skipping invalid PID', { pid });
           continue;
         }
-        execSync(`taskkill /PID ${pid} /T /F`, { timeout: 5000, stdio: 'ignore' });
+        execSync(`taskkill /PID ${pid} /T /F`, { timeout: 60000, stdio: 'ignore' });
       }
     } else {
       await execAsync(`kill ${pids.join(' ')}`);
@@ -463,11 +463,11 @@ export class WorkerService {
         env: process.env
       });
 
-      // Add timeout guard to prevent hanging on MCP connection (15 seconds)
+      // Add timeout guard to prevent hanging on MCP connection (5 minutes for slow systems)
-      const MCP_INIT_TIMEOUT_MS = 15000;
+      const MCP_INIT_TIMEOUT_MS = 300000;
       const mcpConnectionPromise = this.mcpClient.connect(transport);
       const timeoutPromise = new Promise<never>((_, reject) =>
-        setTimeout(() => reject(new Error('MCP connection timeout after 15s')), MCP_INIT_TIMEOUT_MS)
+        setTimeout(() => reject(new Error('MCP connection timeout after 5 minutes')), MCP_INIT_TIMEOUT_MS)
       );
 
       await Promise.race([mcpConnectionPromise, timeoutPromise]);
@@ -652,7 +652,7 @@ export class WorkerService {
     }
 
     const cmd = `powershell -Command "Get-CimInstance Win32_Process | Where-Object { $_.ParentProcessId -eq ${parentPid} } | Select-Object -ExpandProperty ProcessId"`;
-    const { stdout } = await execAsync(cmd, { timeout: 5000 });
+    const { stdout } = await execAsync(cmd, { timeout: 60000 });
     return stdout
       .trim()
       .split('\n')
@@ -672,7 +672,7 @@ export class WorkerService {
 
     if (process.platform === 'win32') {
       // /T kills entire process tree, /F forces termination
-      await execAsync(`taskkill /PID ${pid} /T /F`, { timeout: 5000 });
+      await execAsync(`taskkill /PID ${pid} /T /F`, { timeout: 60000 });
       logger.info('SYSTEM', 'Killed process', { pid });
     } else {
       process.kill(pid, 'SIGKILL');

src/services/worker/BranchManager.ts

@@ -28,9 +28,9 @@ function isValidBranchName(branchName: string): boolean {
   return validBranchRegex.test(branchName) && !branchName.includes('..');
 }
 
-// Timeout constants
+// Timeout constants (increased for slow systems)
-const GIT_COMMAND_TIMEOUT_MS = 30_000;
+const GIT_COMMAND_TIMEOUT_MS = 300_000;
-const NPM_INSTALL_TIMEOUT_MS = 120_000;
+const NPM_INSTALL_TIMEOUT_MS = 600_000;
 const DEFAULT_SHELL_TIMEOUT_MS = 60_000;
 
 export interface BranchInfo {

src/shared/hook-constants.ts

@@ -1,8 +1,8 @@
 export const HOOK_TIMEOUTS = {
-  DEFAULT: 120000,            // Standard HTTP timeout (up from 2000ms)
+  DEFAULT: 300000,            // Standard HTTP timeout (5 min for slow systems)
-  HEALTH_CHECK: 1000,         // Worker health check (up from 500ms)
+  HEALTH_CHECK: 30000,        // Worker health check (30s for slow systems)
   WORKER_STARTUP_WAIT: 1000,
-  WORKER_STARTUP_RETRIES: 15,
+  WORKER_STARTUP_RETRIES: 300,
   PRE_RESTART_SETTLE_DELAY: 2000,  // Give files time to sync before restart
   WINDOWS_MULTIPLIER: 1.5     // Platform-specific adjustment
 } as const;