fix: large tool inputs break bash PTC replay and pending-call serialization

service/scripts/test-ptc-replay-bash-smoke.ts

@@ -519,5 +519,37 @@ get_weather '{"city":"Rome"}'
   );
 }
 
+{
+  // Regression: input past ARG_MAX (~128KB) must still replay from history,
+  // not get silently re-issued as a new pending call each run.
+  const bigExpr = '1+1;#' + 'x'.repeat(300_000);
+  const user = `
+result=$(calculate '{"expression":"${bigExpr}"}')
+echo "Result: $result"
+`;
+  const r1 = runBash(assemble(user), {});
+  const p1 = extractPending(r1.stdout);
+  assert(r1.exitCode === 0, 'large_input: first run exit 0');
+  assert(p1.pending?.[0]?.call_id === 'call_001', 'large_input: first pending is call_001');
+  assert(
+    typeof p1.pending?.[0]?.input_hash === 'string' && p1.pending[0].input_hash.length === 64,
+    'large_input: pending carries a hash for the oversized input',
+  );
+
+  const history = {
+    call_001: {
+      result: 'ok-large',
+      tool_name: 'calculate',
+      input_hash: hashToolInput({ expression: bigExpr }),
+      received_at: 1,
+    },
+  };
+  const r2 = runBash(assemble(user), history);
+  const p2 = extractPending(r2.stdout);
+  assert(r2.exitCode === 0, 'large_input_replay: exit 0');
+  assert(p2.pending === null, 'large_input_replay: no pending re-emitted for the same oversized call');
+  assert(p2.stdout.includes('Result: "ok-large"'), 'large_input_replay: cached result used instead of re-invoking');
+}
+
 console.log(`\n${passed} passed, ${failed} failed`);
 if (failed > 0) process.exit(1);

service/src/config.ts

@@ -273,6 +273,9 @@ export const env = {
   EGRESS_GATEWAY_FILE_SERVER_URL: process.env.EGRESS_GATEWAY_FILE_SERVER_URL ?? process.env.FILE_SERVER_URL ?? 'http://localhost:3000',
   EGRESS_GATEWAY_TOOL_CALL_SERVER_URL: process.env.EGRESS_GATEWAY_TOOL_CALL_SERVER_URL ?? process.env.TOOL_CALL_SERVER_URL ?? 'http://localhost:3033',
   EGRESS_GATEWAY_MAX_TOOL_CALL_BYTES: Number(process.env.EGRESS_GATEWAY_MAX_TOOL_CALL_BYTES) || 1024 * 1024,
+  // Per-entry / aggregate caps for PTC tool results persisted in `tool_history:` (see replay-state.ts).
+  PTC_MAX_TOOL_RESULT_BYTES: Number(process.env.PTC_MAX_TOOL_RESULT_BYTES) || 5_000_000,
+  PTC_MAX_TOOL_HISTORY_TOTAL_BYTES: Number(process.env.PTC_MAX_TOOL_HISTORY_TOTAL_BYTES) || 40_000_000,
   EGRESS_GATEWAY_MAX_FILE_BYTES: Number(process.env.EGRESS_GATEWAY_MAX_FILE_BYTES ?? process.env.SANDBOX_MAX_FILE_SIZE) || 10_000_000,
   EGRESS_GATEWAY_MAX_PATH_LENGTH: Number(process.env.EGRESS_GATEWAY_MAX_PATH_LENGTH ?? process.env.SANDBOX_MAX_PATH_LENGTH) || 256,
   EGRESS_GATEWAY_MAX_NESTING_DEPTH: Number(process.env.EGRESS_GATEWAY_MAX_NESTING_DEPTH ?? process.env.SANDBOX_MAX_NESTING_DEPTH) || 10,

service/src/preamble-bash.ts

@@ -417,18 +417,20 @@ _ptc_next_call_id() {
 
 _ptc_history_matches_by_signature() {
     local _ptc_name="$1"
-    local _ptc_input="$2"
+    local _ptc_input_file="$2"
     local _ptc_input_hash="$3"
     local _ptc_call_site="$4"
     if [ ! -r "$_PTC_HISTORY_PATH" ]; then
         return 0
     fi
+    # Path, not inline: large input can exceed ARG_MAX via --argjson.
     jq -c \\
         --arg nm "$_ptc_name" \\
         --arg site "$_ptc_call_site" \\
         --arg hash "$_ptc_input_hash" \\
-        --argjson inp "$_ptc_input" \\
-        'to_entries
+        --slurpfile inp_arr "$_ptc_input_file" \\
+        '($inp_arr[0]) as $inp
+         | to_entries
          | map(select((.value | type) == "object"
              and .value.tool_name == $nm
              and ((.value.input_hash == $hash) or (.value.input == $inp))))
@@ -474,13 +476,15 @@ _ptc_print_history_entry() {
 _ptc_history_entry_matches_current_call() {
     local _ptc_entry="$1"
     local _ptc_name="$2"
-    local _ptc_input="$3"
+    local _ptc_input_file="$3"
     local _ptc_input_hash="$4"
+    # Path, same ARG_MAX reason as above.
     printf '%s' "$_ptc_entry" | jq -e \\
         --arg nm "$_ptc_name" \\
         --arg hash "$_ptc_input_hash" \\
-        --argjson inp "$_ptc_input" \\
-        'if type != "object" then true
+        --slurpfile inp_arr "$_ptc_input_file" \\
+        '($inp_arr[0]) as $inp
+         | if type != "object" then true
          elif (has("tool_name") and .tool_name != $nm) then false
          elif (has("input_hash") or has("input")) then
            ((.input_hash == $hash) or (.input == $inp))
@@ -505,8 +509,13 @@ _ptc_call_tool() {
         exit 1
     fi
 
+    # Large input can exceed ARG_MAX via --argjson; write once, reuse path below.
+    local _ptc_input_tmp
+    _ptc_input_tmp="$(mktemp -t _ptc_input.XXXXXX 2>/dev/null || mktemp /tmp/_ptc_input.XXXXXX)"
+    printf '%s' "$_ptc_input" > "$_ptc_input_tmp"
+
     local _ptc_matches
-    _ptc_matches=$(_ptc_history_matches_by_signature "$_ptc_name" "$_ptc_input" "$_ptc_input_hash" "$_ptc_call_site")
+    _ptc_matches=$(_ptc_history_matches_by_signature "$_ptc_name" "$_ptc_input_tmp" "$_ptc_input_hash" "$_ptc_call_site")
 
     if ! _ptc_acquire_lock; then
         exit 1
@@ -522,6 +531,7 @@ _ptc_call_tool() {
         printf '%s\\n' "$_ptc_matched_call_id" >> "$_PTC_CONSUMED_FILE"
         _ptc_mark_counter_at_least "$_ptc_matched_call_id"
         _ptc_release_lock
+        rm -f "$_ptc_input_tmp"
         _ptc_print_history_entry "$_ptc_matched_entry"
         return $?
     fi
@@ -538,26 +548,28 @@ _ptc_call_tool() {
         if [ -z "$_ptc_entry" ] || [ "$_ptc_entry" = "null" ]; then
             break
         fi
-        if _ptc_history_entry_matches_current_call "$_ptc_entry" "$_ptc_name" "$_ptc_input" "$_ptc_input_hash"; then
+        if _ptc_history_entry_matches_current_call "$_ptc_entry" "$_ptc_name" "$_ptc_input_tmp" "$_ptc_input_hash"; then
             printf '%s\\n' "$_ptc_call_id" >> "$_PTC_CONSUMED_FILE"
             _ptc_release_lock
+            rm -f "$_ptc_input_tmp"
             _ptc_print_history_entry "$_ptc_entry"
             return $?
         fi
     done
 
-    if ! jq -c -n \\
+    if ! printf '%s' "$_ptc_input" | jq -c -n \\
         --arg cid "$_ptc_call_id" \\
         --arg nm "$_ptc_name" \\
         --arg hash "$_ptc_input_hash" \\
         --arg site "$_ptc_call_site" \\
-        --argjson inp "$_ptc_input" \\
-        '{call_id:$cid,tool_name:$nm,input:$inp,input_hash:$hash,call_site:$site}' >> "$_PTC_PENDING_FILE"; then
+        '{call_id:$cid,tool_name:$nm,input:input,input_hash:$hash,call_site:$site}' >> "$_PTC_PENDING_FILE"; then
         _ptc_write_error "failed to serialize pending tool call for $_ptc_name"
         _ptc_release_lock
+        rm -f "$_ptc_input_tmp"
         exit 1
     fi
     _ptc_release_lock
+    rm -f "$_ptc_input_tmp"
     exit 0
 }
 

service/src/service/replay-state.ts

@@ -60,13 +60,13 @@ export const REPLAY_LOCK_TTL_MS = Math.max(10 * 60 * 1000, env.JOB_TIMEOUT * 2 +
  * Redis hash and the `_ptc_history.json` injected into the sandbox bounded
  * regardless of how pathological a single tool result is. Scaled
  * proportionally with `MAX_EXECUTION_STATE_BYTES` (ratio 1:2 vs exec_state). */
-export const MAX_TOOL_RESULT_BYTES = 5_000_000;
+export const MAX_TOOL_RESULT_BYTES = env.PTC_MAX_TOOL_RESULT_BYTES;
 
 /** Aggregate cap across ALL results persisted for a single execution. Scaled
  * proportionally with `MAX_EXECUTION_STATE_BYTES` (ratio 4:1 vs exec_state)
  * so a long replay flow can accumulate ~8 saturating tool results before
  * being asked to break work into a fresh execution. */
-export const MAX_TOOL_HISTORY_TOTAL_BYTES = 40_000_000;
+export const MAX_TOOL_HISTORY_TOTAL_BYTES = env.PTC_MAX_TOOL_HISTORY_TOTAL_BYTES;
 
 /** Maximum number of keys `scanKeys` will return in a single call. The janitor
  * runs every `STALE_CLEANUP_INTERVAL` and processes whatever this yields; if