fix: two process leaks (agent-browser daemons, paste.rs sleepers) (#11843)

Both fixes close process leaks observed in production (18+ orphaned
agent-browser node daemons, 15+ orphaned paste.rs sleep interpreters
accumulated over ~3 days, ~2.7 GB RSS).

## agent-browser daemon leak

Previously the orphan reaper (_reap_orphaned_browser_sessions) only ran
from _start_browser_cleanup_thread, which is only invoked on the first
browser tool call in a process. Hermes sessions that never used the
browser never swept orphans, and the cross-process orphan detection
relied on in-process _active_sessions, which doesn't see other hermes
PIDs' sessions (race risk).

- Write <session>.owner_pid alongside the socket dir recording the
  hermes PID that owns the daemon (extracted into _write_owner_pid for
  direct testability).
- Reaper prefers owner_pid liveness over in-process _active_sessions.
  Cross-process safe: concurrent hermes instances won't reap each
  other's daemons. Legacy tracked_names fallback kept for daemons
  that predate owner_pid.
- atexit handler (_emergency_cleanup_all_sessions) now always runs
  the reaper, not just when this process had active sessions —
  every clean hermes exit sweeps accumulated orphans.

## paste.rs auto-delete leak

_schedule_auto_delete spawned a detached Python subprocess per call
that slept 6 hours then issued DELETE requests. No dedup, no tracking —
every 'hermes debug share' invocation added ~20 MB of resident Python
interpreters that stuck around until the sleep finished.

- Replaced the spawn with ~/.hermes/pastes/pending.json: records
  {url, expire_at} entries.
- _sweep_expired_pastes() synchronously DELETEs past-due entries on
  every 'hermes debug' invocation (run_debug() dispatcher).
- Network failures stay in pending.json for up to 24h, then give up
  (paste.rs's own retention handles the 'user never runs hermes again'
  edge case).
- Zero subprocesses; regression test asserts subprocess/Popen/time.sleep
  never appear in the function source (skipping docstrings via AST).

## Validation

|                              | Before        | After        |
|------------------------------|---------------|--------------|
| Orphan agent-browser daemons | 18 accumulated| 2 (live)     |
| paste.rs sleep interpreters  | 15 accumulated| 0            |
| RSS reclaimed                | -             | ~2.7 GB      |
| Targeted tests               | -             | 2253 pass    |

E2E verified: alive-owner daemons NOT reaped; dead-owner daemons
SIGTERM'd and socket dirs cleaned; pending.json sweep deletes expired
entries without spawning subprocesses.

hermes_cli/debug.py

@@ -6,7 +6,10 @@ Currently supports:
 """
 
 import io
+import json
+import os
 import sys
+import time
 import urllib.error
 import urllib.parse
 import urllib.request
@@ -31,6 +34,119 @@ _MAX_LOG_BYTES = 512_000
 _AUTO_DELETE_SECONDS = 21600
 
 
+# ---------------------------------------------------------------------------
+# Pending-deletion tracking (replaces the old fork-and-sleep subprocess).
+# ---------------------------------------------------------------------------
+
+def _pending_file() -> Path:
+    """Path to ``~/.hermes/pastes/pending.json``.
+
+    Each entry: ``{"url": "...", "expire_at": <unix_ts>}``.  Scheduled
+    DELETEs used to be handled by spawning a detached Python process per
+    paste that slept for 6 hours; those accumulated forever if the user
+    ran ``hermes debug share`` repeatedly.  We now persist the schedule
+    to disk and sweep expired entries on the next debug invocation.
+    """
+    return get_hermes_home() / "pastes" / "pending.json"
+
+
+def _load_pending() -> list[dict]:
+    path = _pending_file()
+    if not path.exists():
+        return []
+    try:
+        data = json.loads(path.read_text(encoding="utf-8"))
+        if isinstance(data, list):
+            # Filter to well-formed entries only
+            return [
+                e for e in data
+                if isinstance(e, dict) and "url" in e and "expire_at" in e
+            ]
+    except (OSError, ValueError, json.JSONDecodeError):
+        pass
+    return []
+
+
+def _save_pending(entries: list[dict]) -> None:
+    path = _pending_file()
+    try:
+        path.parent.mkdir(parents=True, exist_ok=True)
+        tmp = path.with_suffix(".json.tmp")
+        tmp.write_text(json.dumps(entries, indent=2), encoding="utf-8")
+        os.replace(tmp, path)
+    except OSError:
+        # Non-fatal — worst case the user has to run ``hermes debug delete``
+        # manually.
+        pass
+
+
+def _record_pending(urls: list[str], delay_seconds: int = _AUTO_DELETE_SECONDS) -> None:
+    """Record *urls* for deletion at ``now + delay_seconds``.
+
+    Only paste.rs URLs are recorded (dpaste.com auto-expires).  Entries
+    are merged into any existing pending.json.
+    """
+    paste_rs_urls = [u for u in urls if _extract_paste_id(u)]
+    if not paste_rs_urls:
+        return
+
+    entries = _load_pending()
+    # Dedupe by URL: keep the later expire_at if same URL appears twice
+    by_url: dict[str, float] = {e["url"]: float(e["expire_at"]) for e in entries}
+    expire_at = time.time() + delay_seconds
+    for u in paste_rs_urls:
+        by_url[u] = max(expire_at, by_url.get(u, 0.0))
+    merged = [{"url": u, "expire_at": ts} for u, ts in by_url.items()]
+    _save_pending(merged)
+
+
+def _sweep_expired_pastes(now: Optional[float] = None) -> tuple[int, int]:
+    """Synchronously DELETE any pending pastes whose ``expire_at`` has passed.
+
+    Returns ``(deleted, remaining)``.  Best-effort: failed deletes stay in
+    the pending file and will be retried on the next sweep.  Silent —
+    intended to be called from every ``hermes debug`` invocation with
+    minimal noise.
+    """
+    entries = _load_pending()
+    if not entries:
+        return (0, 0)
+
+    current = time.time() if now is None else now
+    deleted = 0
+    remaining: list[dict] = []
+
+    for entry in entries:
+        try:
+            expire_at = float(entry.get("expire_at", 0))
+        except (TypeError, ValueError):
+            continue  # drop malformed entries
+        if expire_at > current:
+            remaining.append(entry)
+            continue
+
+        url = entry.get("url", "")
+        try:
+            if delete_paste(url):
+                deleted += 1
+                continue
+        except Exception:
+            # Network hiccup, 404 (already gone), etc. — drop the entry
+            # after a grace period; don't retry forever.
+            pass
+
+        # Retain failed deletes for up to 24h past expiration, then give up.
+        if expire_at + 86400 > current:
+            remaining.append(entry)
+        else:
+            deleted += 1  # count as reaped (paste.rs will GC eventually)
+
+    if deleted:
+        _save_pending(remaining)
+
+    return (deleted, len(remaining))
+
+
 # ---------------------------------------------------------------------------
 # Privacy / delete helpers
 # ---------------------------------------------------------------------------
@@ -90,37 +206,19 @@ def delete_paste(url: str) -> bool:
 
 
 def _schedule_auto_delete(urls: list[str], delay_seconds: int = _AUTO_DELETE_SECONDS):
-    """Spawn a detached process to delete paste.rs pastes after *delay_seconds*.
+    """Record *urls* for deletion ``delay_seconds`` from now.
 
-    The child process is fully detached (``start_new_session=True``) so it
-    survives the parent exiting (important for CLI mode).  Only paste.rs
-    URLs are attempted — dpaste.com pastes auto-expire on their own.
+    Previously this spawned a detached Python subprocess per call that slept
+    for 6 hours and then issued DELETE requests.  Those subprocesses leaked —
+    every ``hermes debug share`` invocation added ~20 MB of resident Python
+    interpreters that never exited until the sleep completed.
+
+    The replacement is stateless: we append to ``~/.hermes/pastes/pending.json``
+    and rely on opportunistic sweeps (``_sweep_expired_pastes``) called from
+    every ``hermes debug`` invocation.  If the user never runs ``hermes debug``
+    again, paste.rs's own retention policy handles cleanup.
     """
-    import subprocess
-
-    paste_rs_urls = [u for u in urls if _extract_paste_id(u)]
-    if not paste_rs_urls:
-        return
-
-    # Build a tiny inline Python script.  No imports beyond stdlib.
-    url_list = ", ".join(f'"{u}"' for u in paste_rs_urls)
-    script = (
-        "import time, urllib.request; "
-        f"time.sleep({delay_seconds}); "
-        f"[urllib.request.urlopen(urllib.request.Request(u, method='DELETE', "
-        f"headers={{'User-Agent': 'hermes-agent/auto-delete'}}), timeout=15) "
-        f"for u in [{url_list}]]"
-    )
-
-    try:
-        subprocess.Popen(
-            [sys.executable, "-c", script],
-            start_new_session=True,
-            stdout=subprocess.DEVNULL,
-            stderr=subprocess.DEVNULL,
-        )
-    except Exception:
-        pass  # Best-effort; manual delete still available.
+    _record_pending(urls, delay_seconds=delay_seconds)
 
 
 def _delete_hint(url: str) -> str:
@@ -455,6 +553,16 @@ def run_debug_delete(args):
 
 def run_debug(args):
     """Route debug subcommands."""
+    # Opportunistic sweep of expired pastes on every ``hermes debug`` call.
+    # Replaces the old per-paste sleeping subprocess that used to leak as
+    # one orphaned Python interpreter per scheduled deletion.  Silent and
+    # best-effort — any failure is swallowed so ``hermes debug`` stays
+    # reliable even when offline.
+    try:
+        _sweep_expired_pastes()
+    except Exception:
+        pass
+
     subcmd = getattr(args, "debug_command", None)
     if subcmd == "share":
         run_debug_share(args)

tests/hermes_cli/test_debug.py

@@ -501,40 +501,272 @@ class TestDeletePaste:
 
 
 class TestScheduleAutoDelete:
-    def test_spawns_detached_process(self):
+    """``_schedule_auto_delete`` used to spawn a detached Python subprocess
+    per call (one per paste URL batch).  Those subprocesses slept 6 hours
+    and accumulated forever under repeated use — 15+ orphaned interpreters
+    were observed in production.
+
+    The new implementation is stateless: it records pending deletions to
+    ``~/.hermes/pastes/pending.json`` and lets ``_sweep_expired_pastes``
+    handle the DELETE requests synchronously on the next ``hermes debug``
+    invocation.
+    """
+
+    def test_does_not_spawn_subprocess(self, hermes_home):
+        """Regression guard: _schedule_auto_delete must NEVER spawn subprocesses.
+
+        We assert this structurally rather than by mocking Popen: the new
+        implementation doesn't even import ``subprocess`` at module scope,
+        so a mock patch wouldn't find it.
+        """
+        import ast
+        import inspect
         from hermes_cli.debug import _schedule_auto_delete
 
-        with patch("subprocess.Popen") as mock_popen:
-            _schedule_auto_delete(
-                ["https://paste.rs/abc", "https://paste.rs/def"],
-                delay_seconds=10,
-            )
+        # Strip the docstring before scanning so the regression-rationale
+        # prose inside it doesn't trigger our banned-word checks.
+        source = inspect.getsource(_schedule_auto_delete)
+        tree = ast.parse(source)
+        func_node = tree.body[0]
+        if (
+            func_node.body
+            and isinstance(func_node.body[0], ast.Expr)
+            and isinstance(func_node.body[0].value, ast.Constant)
+            and isinstance(func_node.body[0].value.value, str)
+        ):
+            func_node.body = func_node.body[1:]
+        code_only = ast.unparse(func_node)
 
-        mock_popen.assert_called_once()
-        call_args = mock_popen.call_args
-        # Verify detached
-        assert call_args[1]["start_new_session"] is True
-        # Verify the script references both URLs
-        script = call_args[0][0][2]  # [python, -c, script]
-        assert "paste.rs/abc" in script
-        assert "paste.rs/def" in script
-        assert "time.sleep(10)" in script
+        assert "Popen" not in code_only, (
+            "_schedule_auto_delete must not spawn subprocesses — "
+            "use pending.json + _sweep_expired_pastes instead"
+        )
+        assert "subprocess" not in code_only, (
+            "_schedule_auto_delete must not reference subprocess at all"
+        )
+        assert "time.sleep" not in code_only, (
+            "Regression: sleeping in _schedule_auto_delete is the bug being fixed"
+        )
 
-    def test_skips_non_paste_rs_urls(self):
-        from hermes_cli.debug import _schedule_auto_delete
+        # And verify that calling it doesn't produce any orphaned children
+        # (it should just write pending.json synchronously).
+        import os as _os
+        before = set(_os.listdir("/proc")) if _os.path.exists("/proc") else None
+        _schedule_auto_delete(
+            ["https://paste.rs/abc", "https://paste.rs/def"],
+            delay_seconds=10,
+        )
+        if before is not None:
+            after = set(_os.listdir("/proc"))
+            new = after - before
+            # Filter to only integer-named entries (process PIDs)
+            new_pids = [p for p in new if p.isdigit()]
+            # It's fine if unrelated processes appeared — we just need to make
+            # sure we didn't spawn a long-sleeping one.  The old bug spawned
+            # a python interpreter whose cmdline contained "time.sleep".
+            for pid in new_pids:
+                try:
+                    with open(f"/proc/{pid}/cmdline", "rb") as f:
+                        cmdline = f.read().decode("utf-8", errors="replace")
+                    assert "time.sleep" not in cmdline, (
+                        f"Leaked sleeper subprocess PID {pid}: {cmdline}"
+                    )
+                except OSError:
+                    pass  # process exited already
 
-        with patch("subprocess.Popen") as mock_popen:
-            _schedule_auto_delete(["https://dpaste.com/something"])
+    def test_records_pending_to_json(self, hermes_home):
+        """Scheduled URLs are persisted to pending.json with expiration."""
+        from hermes_cli.debug import _schedule_auto_delete, _pending_file
+        import json
 
-        mock_popen.assert_not_called()
+        _schedule_auto_delete(
+            ["https://paste.rs/abc", "https://paste.rs/def"],
+            delay_seconds=10,
+        )
 
-    def test_handles_popen_failure_gracefully(self):
-        from hermes_cli.debug import _schedule_auto_delete
+        pending_path = _pending_file()
+        assert pending_path.exists()
 
-        with patch("subprocess.Popen",
-                    side_effect=OSError("no such file")):
-            # Should not raise
-            _schedule_auto_delete(["https://paste.rs/abc"])
+        entries = json.loads(pending_path.read_text())
+        assert len(entries) == 2
+        urls = {e["url"] for e in entries}
+        assert urls == {"https://paste.rs/abc", "https://paste.rs/def"}
+
+        # expire_at is ~now + delay_seconds
+        import time
+        for e in entries:
+            assert e["expire_at"] > time.time()
+            assert e["expire_at"] <= time.time() + 15
+
+    def test_skips_non_paste_rs_urls(self, hermes_home):
+        """dpaste.com URLs auto-expire — don't track them."""
+        from hermes_cli.debug import _schedule_auto_delete, _pending_file
+
+        _schedule_auto_delete(["https://dpaste.com/something"])
+
+        # pending.json should not be created for non-paste.rs URLs
+        assert not _pending_file().exists()
+
+    def test_merges_with_existing_pending(self, hermes_home):
+        """Subsequent calls merge into existing pending.json."""
+        from hermes_cli.debug import _schedule_auto_delete, _load_pending
+
+        _schedule_auto_delete(["https://paste.rs/first"], delay_seconds=10)
+        _schedule_auto_delete(["https://paste.rs/second"], delay_seconds=10)
+
+        entries = _load_pending()
+        urls = {e["url"] for e in entries}
+        assert urls == {"https://paste.rs/first", "https://paste.rs/second"}
+
+    def test_dedupes_same_url(self, hermes_home):
+        """Same URL recorded twice → one entry with the later expire_at."""
+        from hermes_cli.debug import _schedule_auto_delete, _load_pending
+
+        _schedule_auto_delete(["https://paste.rs/dup"], delay_seconds=10)
+        _schedule_auto_delete(["https://paste.rs/dup"], delay_seconds=100)
+
+        entries = _load_pending()
+        assert len(entries) == 1
+        assert entries[0]["url"] == "https://paste.rs/dup"
+
+
+class TestSweepExpiredPastes:
+    """Test the opportunistic sweep that replaces the sleeping subprocess."""
+
+    def test_sweep_empty_is_noop(self, hermes_home):
+        from hermes_cli.debug import _sweep_expired_pastes
+
+        deleted, remaining = _sweep_expired_pastes()
+        assert deleted == 0
+        assert remaining == 0
+
+    def test_sweep_deletes_expired_entries(self, hermes_home):
+        from hermes_cli.debug import (
+            _sweep_expired_pastes,
+            _save_pending,
+            _load_pending,
+        )
+        import time
+
+        # Seed pending.json with one expired + one future entry
+        _save_pending([
+            {"url": "https://paste.rs/expired", "expire_at": time.time() - 100},
+            {"url": "https://paste.rs/future", "expire_at": time.time() + 3600},
+        ])
+
+        delete_calls = []
+
+        def fake_delete(url):
+            delete_calls.append(url)
+            return True
+
+        with patch("hermes_cli.debug.delete_paste", side_effect=fake_delete):
+            deleted, remaining = _sweep_expired_pastes()
+
+        assert delete_calls == ["https://paste.rs/expired"]
+        assert deleted == 1
+        assert remaining == 1
+
+        entries = _load_pending()
+        urls = {e["url"] for e in entries}
+        assert urls == {"https://paste.rs/future"}
+
+    def test_sweep_leaves_future_entries_alone(self, hermes_home):
+        from hermes_cli.debug import _sweep_expired_pastes, _save_pending
+        import time
+
+        _save_pending([
+            {"url": "https://paste.rs/future1", "expire_at": time.time() + 3600},
+            {"url": "https://paste.rs/future2", "expire_at": time.time() + 7200},
+        ])
+
+        with patch("hermes_cli.debug.delete_paste") as mock_delete:
+            deleted, remaining = _sweep_expired_pastes()
+
+        mock_delete.assert_not_called()
+        assert deleted == 0
+        assert remaining == 2
+
+    def test_sweep_survives_network_failure(self, hermes_home):
+        """Failed DELETEs stay in pending.json until the 24h grace window."""
+        from hermes_cli.debug import (
+            _sweep_expired_pastes,
+            _save_pending,
+            _load_pending,
+        )
+        import time
+
+        _save_pending([
+            {"url": "https://paste.rs/flaky", "expire_at": time.time() - 100},
+        ])
+
+        with patch(
+            "hermes_cli.debug.delete_paste",
+            side_effect=Exception("network down"),
+        ):
+            deleted, remaining = _sweep_expired_pastes()
+
+        # Failure within 24h grace → kept for retry
+        assert deleted == 0
+        assert remaining == 1
+        assert len(_load_pending()) == 1
+
+    def test_sweep_drops_entries_past_grace_window(self, hermes_home):
+        """After 24h past expiration, give up even on network failures."""
+        from hermes_cli.debug import (
+            _sweep_expired_pastes,
+            _save_pending,
+            _load_pending,
+        )
+        import time
+
+        # Expired 25 hours ago → past the 24h grace window
+        very_old = time.time() - (25 * 3600)
+        _save_pending([
+            {"url": "https://paste.rs/ancient", "expire_at": very_old},
+        ])
+
+        with patch(
+            "hermes_cli.debug.delete_paste",
+            side_effect=Exception("network down"),
+        ):
+            deleted, remaining = _sweep_expired_pastes()
+
+        assert deleted == 1
+        assert remaining == 0
+        assert _load_pending() == []
+
+
+class TestRunDebugSweepsOnInvocation:
+    """``run_debug`` must sweep expired pastes on every invocation."""
+
+    def test_run_debug_calls_sweep(self, hermes_home):
+        from hermes_cli.debug import run_debug
+
+        args = MagicMock()
+        args.debug_command = None  # default → prints help
+
+        with patch("hermes_cli.debug._sweep_expired_pastes") as mock_sweep:
+            run_debug(args)
+
+        mock_sweep.assert_called_once()
+
+    def test_run_debug_survives_sweep_failure(self, hermes_home, capsys):
+        """If the sweep throws, the subcommand still runs."""
+        from hermes_cli.debug import run_debug
+
+        args = MagicMock()
+        args.debug_command = None
+
+        with patch(
+            "hermes_cli.debug._sweep_expired_pastes",
+            side_effect=RuntimeError("boom"),
+        ):
+            run_debug(args)  # must not raise
+
+        # Default subcommand still printed help
+        out = capsys.readouterr().out
+        assert "Usage: hermes debug" in out
 
 
 class TestRunDebugDelete:

tests/tools/test_browser_orphan_reaper.py

@@ -28,12 +28,22 @@ def _isolate_sessions():
     bt._active_sessions.update(orig)
 
 
-def _make_socket_dir(tmpdir, session_name, pid=None):
-    """Create a fake agent-browser socket directory with optional PID file."""
+def _make_socket_dir(tmpdir, session_name, pid=None, owner_pid=None):
+    """Create a fake agent-browser socket directory with optional PID files.
+
+    Args:
+        tmpdir: base temp directory
+        session_name: name like "h_abc1234567" or "cdp_abc1234567"
+        pid: daemon PID to write to <session>.pid (None = no file)
+        owner_pid: owning hermes PID to write to <session>.owner_pid
+                   (None = no file; tests the legacy path)
+    """
     d = tmpdir / f"agent-browser-{session_name}"
     d.mkdir()
     if pid is not None:
         (d / f"{session_name}.pid").write_text(str(pid))
+    if owner_pid is not None:
+        (d / f"{session_name}.owner_pid").write_text(str(owner_pid))
     return d
 
 
@@ -62,7 +72,10 @@ class TestReapOrphanedBrowserSessions:
         assert not d.exists()
 
     def test_orphaned_alive_daemon_is_killed(self, fake_tmpdir):
-        """Alive daemon not tracked by _active_sessions gets SIGTERM."""
+        """Alive daemon not tracked by _active_sessions gets SIGTERM (legacy path).
+
+        No owner_pid file => falls back to tracked_names check.
+        """
         from tools.browser_tool import _reap_orphaned_browser_sessions
 
         d = _make_socket_dir(fake_tmpdir, "h_orphan12345", pid=12345)
@@ -84,7 +97,7 @@ class TestReapOrphanedBrowserSessions:
         assert (12345, signal.SIGTERM) in kill_calls
 
     def test_tracked_session_is_not_reaped(self, fake_tmpdir):
-        """Sessions tracked in _active_sessions are left alone."""
+        """Sessions tracked in _active_sessions are left alone (legacy path)."""
         import tools.browser_tool as bt
         from tools.browser_tool import _reap_orphaned_browser_sessions
 
@@ -156,3 +169,240 @@ class TestReapOrphanedBrowserSessions:
 
         _reap_orphaned_browser_sessions()
         assert not d.exists()
+
+
+class TestOwnerPidCrossProcess:
+    """Tests for owner_pid-based cross-process safe reaping.
+
+    The owner_pid file records which hermes process owns a daemon so that
+    concurrent hermes processes don't reap each other's active browser
+    sessions.  Added to fix orphan accumulation from crashed processes.
+    """
+
+    def test_alive_owner_is_not_reaped_even_when_untracked(self, fake_tmpdir):
+        """Daemon with alive owner_pid is NOT reaped, even if not in our _active_sessions.
+
+        This is the core cross-process safety check: Process B scanning while
+        Process A is using a browser must not kill A's daemon.
+        """
+        from tools.browser_tool import _reap_orphaned_browser_sessions
+
+        # Use our own PID as the "owner" — guaranteed alive
+        d = _make_socket_dir(
+            fake_tmpdir, "h_alive_owner", pid=12345, owner_pid=os.getpid()
+        )
+
+        kill_calls = []
+
+        def mock_kill(pid, sig):
+            kill_calls.append((pid, sig))
+            if pid == os.getpid() and sig == 0:
+                return  # real existence check: owner alive
+            if sig == 0:
+                return  # pretend daemon exists too
+            # Don't actually kill anything
+
+        with patch("os.kill", side_effect=mock_kill):
+            _reap_orphaned_browser_sessions()
+
+        # We should have checked the owner (sig 0) but never tried to kill
+        # the daemon.
+        assert (12345, signal.SIGTERM) not in kill_calls
+        # Dir should still exist
+        assert d.exists()
+
+    def test_dead_owner_triggers_reap(self, fake_tmpdir):
+        """Daemon whose owner_pid is dead gets reaped."""
+        from tools.browser_tool import _reap_orphaned_browser_sessions
+
+        # PID 999999999 almost certainly doesn't exist
+        d = _make_socket_dir(
+            fake_tmpdir, "h_dead_owner1", pid=12345, owner_pid=999999999
+        )
+
+        kill_calls = []
+
+        def mock_kill(pid, sig):
+            kill_calls.append((pid, sig))
+            if pid == 999999999 and sig == 0:
+                raise ProcessLookupError  # owner dead
+            if pid == 12345 and sig == 0:
+                return  # daemon still alive
+            # SIGTERM to daemon — noop in test
+
+        with patch("os.kill", side_effect=mock_kill):
+            _reap_orphaned_browser_sessions()
+
+        # Owner checked (returned dead), daemon checked (alive), daemon killed
+        assert (999999999, 0) in kill_calls
+        assert (12345, 0) in kill_calls
+        assert (12345, signal.SIGTERM) in kill_calls
+        # Dir cleaned up
+        assert not d.exists()
+
+    def test_corrupt_owner_pid_falls_back_to_legacy(self, fake_tmpdir):
+        """Corrupt owner_pid file → fall back to tracked_names check."""
+        import tools.browser_tool as bt
+        from tools.browser_tool import _reap_orphaned_browser_sessions
+
+        session_name = "h_corrupt_own"
+        d = _make_socket_dir(fake_tmpdir, session_name, pid=12345)
+        # Write garbage to owner_pid file
+        (d / f"{session_name}.owner_pid").write_text("not-a-pid")
+
+        # Register session so legacy fallback leaves it alone
+        bt._active_sessions["task"] = {"session_name": session_name}
+
+        kill_calls = []
+
+        def mock_kill(pid, sig):
+            kill_calls.append((pid, sig))
+
+        with patch("os.kill", side_effect=mock_kill):
+            _reap_orphaned_browser_sessions()
+
+        # Legacy path took over → tracked → not reaped
+        assert (12345, signal.SIGTERM) not in kill_calls
+        assert d.exists()
+
+    def test_owner_pid_permission_error_treated_as_alive(self, fake_tmpdir):
+        """If os.kill(owner, 0) raises PermissionError, treat owner as alive.
+
+        PermissionError means the PID exists but is owned by a different user —
+        we must not assume the owner is dead (could kill someone else's daemon).
+        """
+        from tools.browser_tool import _reap_orphaned_browser_sessions
+
+        d = _make_socket_dir(
+            fake_tmpdir, "h_perm_owner1", pid=12345, owner_pid=22222
+        )
+
+        kill_calls = []
+
+        def mock_kill(pid, sig):
+            kill_calls.append((pid, sig))
+            if pid == 22222 and sig == 0:
+                raise PermissionError("not our user")
+
+        with patch("os.kill", side_effect=mock_kill):
+            _reap_orphaned_browser_sessions()
+
+        # Must NOT have tried to kill the daemon
+        assert (12345, signal.SIGTERM) not in kill_calls
+        assert d.exists()
+
+    def test_write_owner_pid_creates_file_with_current_pid(
+        self, fake_tmpdir, monkeypatch
+    ):
+        """_write_owner_pid(dir, session) writes <session>.owner_pid with os.getpid()."""
+        import tools.browser_tool as bt
+
+        session_name = "h_ownertest01"
+        socket_dir = fake_tmpdir / f"agent-browser-{session_name}"
+        socket_dir.mkdir()
+
+        bt._write_owner_pid(str(socket_dir), session_name)
+
+        owner_pid_file = socket_dir / f"{session_name}.owner_pid"
+        assert owner_pid_file.exists()
+        assert owner_pid_file.read_text().strip() == str(os.getpid())
+
+    def test_write_owner_pid_is_idempotent(self, fake_tmpdir):
+        """Calling _write_owner_pid twice leaves a single owner_pid file."""
+        import tools.browser_tool as bt
+
+        session_name = "h_idempot1234"
+        socket_dir = fake_tmpdir / f"agent-browser-{session_name}"
+        socket_dir.mkdir()
+
+        bt._write_owner_pid(str(socket_dir), session_name)
+        bt._write_owner_pid(str(socket_dir), session_name)
+
+        files = list(socket_dir.glob("*.owner_pid"))
+        assert len(files) == 1
+        assert files[0].read_text().strip() == str(os.getpid())
+
+    def test_write_owner_pid_swallows_oserror(self, fake_tmpdir, monkeypatch):
+        """OSError (e.g. permission denied) doesn't propagate — the reaper
+        falls back to the legacy tracked_names heuristic in that case.
+        """
+        import tools.browser_tool as bt
+
+        def raise_oserror(*a, **kw):
+            raise OSError("permission denied")
+
+        monkeypatch.setattr("builtins.open", raise_oserror)
+
+        # Must not raise
+        bt._write_owner_pid(str(fake_tmpdir), "h_readonly123")
+
+    def test_run_browser_command_calls_write_owner_pid(
+        self, fake_tmpdir, monkeypatch
+    ):
+        """_run_browser_command wires _write_owner_pid after mkdir."""
+        import tools.browser_tool as bt
+
+        session_name = "h_wiringtest1"
+
+        # Short-circuit Popen so we exit after the owner_pid write
+        class _FakePopen:
+            def __init__(self, *a, **kw):
+                raise RuntimeError("short-circuit after owner_pid")
+
+        monkeypatch.setattr(bt.subprocess, "Popen", _FakePopen)
+        monkeypatch.setattr(bt, "_find_agent_browser", lambda: "/bin/true")
+        monkeypatch.setattr(
+            bt, "_requires_real_termux_browser_install", lambda *a: False
+        )
+        monkeypatch.setattr(
+            bt, "_get_session_info",
+            lambda task_id: {"session_name": session_name},
+        )
+
+        calls = []
+        orig_write = bt._write_owner_pid
+
+        def _spy(*a, **kw):
+            calls.append(a)
+            orig_write(*a, **kw)
+
+        monkeypatch.setattr(bt, "_write_owner_pid", _spy)
+
+        with patch("tools.browser_tool._socket_safe_tmpdir", return_value=str(fake_tmpdir)):
+            try:
+                bt._run_browser_command(task_id="test_task", command="goto", args=[])
+            except Exception:
+                pass
+
+        assert calls, "_run_browser_command must call _write_owner_pid"
+        # First positional arg is the socket_dir, second is the session_name
+        socket_dir_arg, session_name_arg = calls[0][0], calls[0][1]
+        assert session_name_arg == session_name
+        assert session_name in socket_dir_arg
+
+
+class TestEmergencyCleanupRunsReaper:
+    """Verify atexit-registered cleanup sweeps orphans even without an active session."""
+
+    def test_emergency_cleanup_calls_reaper(self, fake_tmpdir, monkeypatch):
+        """_emergency_cleanup_all_sessions must call _reap_orphaned_browser_sessions."""
+        import tools.browser_tool as bt
+
+        # Reset the _cleanup_done flag so the cleanup actually runs
+        monkeypatch.setattr(bt, "_cleanup_done", False)
+
+        reaper_called = []
+        orig_reaper = bt._reap_orphaned_browser_sessions
+
+        def _spy_reaper():
+            reaper_called.append(True)
+            orig_reaper()
+
+        monkeypatch.setattr(bt, "_reap_orphaned_browser_sessions", _spy_reaper)
+
+        # No active sessions — reaper should still run
+        bt._emergency_cleanup_all_sessions()
+
+        assert reaper_called, (
+            "Reaper must run on exit even with no active sessions"
+        )

tools/browser_tool.py

@@ -459,27 +459,38 @@ def _emergency_cleanup_all_sessions():
     """
     Emergency cleanup of all active browser sessions.
     Called on process exit or interrupt to prevent orphaned sessions.
+
+    Also runs the orphan reaper to clean up daemons left behind by previously
+    crashed hermes processes — this way every clean hermes exit sweeps
+    accumulated orphans, not just ones that actively used the browser tool.
     """
     global _cleanup_done
     if _cleanup_done:
         return
     _cleanup_done = True
-    
-    if not _active_sessions:
-        return
-    
-    logger.info("Emergency cleanup: closing %s active session(s)...",
-                len(_active_sessions))
 
+    # Clean up this process's own sessions first, so their owner_pid files
+    # are removed before the reaper scans.
+    if _active_sessions:
+        logger.info("Emergency cleanup: closing %s active session(s)...",
+                    len(_active_sessions))
+        try:
+            cleanup_all_browsers()
+        except Exception as e:
+            logger.error("Emergency cleanup error: %s", e)
+        finally:
+            with _cleanup_lock:
+                _active_sessions.clear()
+                _session_last_activity.clear()
+                _recording_sessions.clear()
+
+    # Sweep orphans from other crashed hermes processes.  Safe even if we
+    # never used the browser — uses owner_pid liveness to avoid reaping
+    # daemons owned by other live hermes processes.
     try:
-        cleanup_all_browsers()
+        _reap_orphaned_browser_sessions()
     except Exception as e:
-        logger.error("Emergency cleanup error: %s", e)
-    finally:
-        with _cleanup_lock:
-            _active_sessions.clear()
-            _session_last_activity.clear()
-            _recording_sessions.clear()
+        logger.debug("Orphan reap on exit failed: %s", e)
 
 
 # Register cleanup via atexit only.  Previous versions installed SIGINT/SIGTERM
@@ -523,6 +534,24 @@ def _cleanup_inactive_browser_sessions():
             logger.warning("Error cleaning up inactive session %s: %s", task_id, e)
 
 
+def _write_owner_pid(socket_dir: str, session_name: str) -> None:
+    """Record the current hermes PID as the owner of a browser socket dir.
+
+    Written atomically to ``<socket_dir>/<session_name>.owner_pid`` so the
+    orphan reaper can distinguish daemons owned by a live hermes process
+    (don't reap) from daemons whose owner crashed (reap).  Best-effort —
+    an OSError here just falls back to the legacy ``tracked_names``
+    heuristic in the reaper.
+    """
+    try:
+        path = os.path.join(socket_dir, f"{session_name}.owner_pid")
+        with open(path, "w") as f:
+            f.write(str(os.getpid()))
+    except OSError as exc:
+        logger.debug("Could not write owner_pid file for %s: %s",
+                     session_name, exc)
+
+
 def _reap_orphaned_browser_sessions():
     """Scan for orphaned agent-browser daemon processes from previous runs.
 
@@ -532,10 +561,19 @@ def _reap_orphaned_browser_sessions():
 
     This function scans the tmp directory for ``agent-browser-*`` socket dirs
     left behind by previous runs, reads the daemon PID files, and kills any
-    daemons that are still alive but not tracked by the current process.
+    daemons whose owning hermes process is no longer alive.
 
-    Called once on cleanup-thread startup — not every 30 seconds — to avoid
-    races with sessions being actively created.
+    Ownership detection priority:
+      1. ``<session>.owner_pid`` file (written by current code) — if the
+         referenced hermes PID is alive, leave the daemon alone regardless
+         of whether it's in *this* process's ``_active_sessions``.  This is
+         cross-process safe: two concurrent hermes instances won't reap each
+         other's daemons.
+      2. Fallback for daemons that predate owner_pid: check
+         ``_active_sessions`` in the current process.  If not tracked here,
+         treat as orphan (legacy behavior).
+
+    Safe to call from any context — atexit, cleanup thread, or on demand.
     """
     import glob
 
@@ -548,7 +586,7 @@ def _reap_orphaned_browser_sessions():
     if not socket_dirs:
         return
 
-    # Build set of session_names currently tracked by this process
+    # Build set of session_names currently tracked by this process (fallback path)
     with _cleanup_lock:
         tracked_names = {
             info.get("session_name")
@@ -564,13 +602,38 @@ def _reap_orphaned_browser_sessions():
         if not session_name:
             continue
 
-        # Skip sessions that we are actively tracking
-        if session_name in tracked_names:
+        # Ownership check: prefer owner_pid file (cross-process safe).
+        owner_pid_file = os.path.join(socket_dir, f"{session_name}.owner_pid")
+        owner_alive: Optional[bool] = None  # None = owner_pid missing/unreadable
+        if os.path.isfile(owner_pid_file):
+            try:
+                owner_pid = int(Path(owner_pid_file).read_text().strip())
+                try:
+                    os.kill(owner_pid, 0)
+                    owner_alive = True
+                except ProcessLookupError:
+                    owner_alive = False
+                except PermissionError:
+                    # Owner exists but we can't signal it (different uid).
+                    # Treat as alive — don't reap someone else's session.
+                    owner_alive = True
+            except (ValueError, OSError):
+                owner_alive = None  # corrupt file — fall through
+
+        if owner_alive is True:
+            # Owner is alive — this session belongs to a live hermes process.
             continue
 
+        if owner_alive is None:
+            # No owner_pid file (legacy daemon).  Fall back to in-process
+            # tracking: if this process knows about the session, leave alone.
+            if session_name in tracked_names:
+                continue
+
+        # owner_alive is False (dead owner) OR legacy daemon not tracked here.
         pid_file = os.path.join(socket_dir, f"{session_name}.pid")
         if not os.path.isfile(pid_file):
-            # No PID file — just a stale dir, remove it
+            # No daemon PID file — just a stale dir, remove it
             shutil.rmtree(socket_dir, ignore_errors=True)
             continue
 
@@ -591,7 +654,7 @@ def _reap_orphaned_browser_sessions():
             # Alive but owned by someone else — leave it alone
             continue
 
-        # Daemon is alive and not tracked — orphan. Kill it.
+        # Daemon is alive and its owner is dead (or legacy + untracked).  Reap.
         try:
             os.kill(daemon_pid, signal.SIGTERM)
             logger.info("Reaped orphaned browser daemon PID %d (session %s)",
@@ -1105,6 +1168,9 @@ def _run_browser_command(
             f"agent-browser-{session_info['session_name']}"
         )
         os.makedirs(task_socket_dir, mode=0o700, exist_ok=True)
+        # Record this hermes PID as the session owner (cross-process safe
+        # orphan detection — see _write_owner_pid).
+        _write_owner_pid(task_socket_dir, session_info['session_name'])
         logger.debug("browser cmd=%s task=%s socket_dir=%s (%d chars)",
                      command, task_id, task_socket_dir, len(task_socket_dir))