feat: health check scans for orphaned Doing/Testing labels (#170)

lib/services/health.ts

@@ -43,7 +43,8 @@ export type HealthIssue = {
     | "stale_worker"         // Case 3: active for >2h
     | "stuck_label"          // Case 4: inactive but issue still has active label
     | "orphan_issue_id"      // Case 5: inactive but issueId set
-    | "issue_gone";          // Case 6: active but issue deleted/closed
+    | "issue_gone"           // Case 6: active but issue deleted/closed
+    | "orphaned_label";      // Case 7: active label but no worker tracking it
   severity: "critical" | "warning";
   project: string;
   groupId: string;
@@ -396,3 +397,88 @@ export async function checkWorkerHealth(opts: {
 
   return fixes;
 }
+
+// ---------------------------------------------------------------------------
+// Orphaned label scan
+// ---------------------------------------------------------------------------
+
+/**
+ * Scan for issues with active labels (Doing, Testing) that are NOT tracked
+ * in projects.json. This catches cases where:
+ * - Worker crashed and state was cleared (issueId: null)
+ * - Label was set externally
+ * - State corruption
+ *
+ * Returns fixes for all orphaned labels found.
+ */
+export async function scanOrphanedLabels(opts: {
+  workspaceDir: string;
+  groupId: string;
+  project: Project;
+  role: Role;
+  autoFix: boolean;
+  provider: IssueProvider;
+  /** Workflow config (defaults to DEFAULT_WORKFLOW) */
+  workflow?: WorkflowConfig;
+}): Promise<HealthFix[]> {
+  const {
+    workspaceDir, groupId, project, role, autoFix, provider,
+    workflow = DEFAULT_WORKFLOW,
+  } = opts;
+
+  const fixes: HealthFix[] = [];
+  const worker = getWorker(project, role);
+
+  // Get labels from workflow config
+  const activeLabel = getActiveLabel(workflow, role);
+  const queueLabel = getRevertLabel(workflow, role);
+
+  // Fetch all issues with the active label
+  let issuesWithLabel: Issue[];
+  try {
+    issuesWithLabel = await provider.listIssuesByLabel(activeLabel);
+  } catch {
+    // Provider error (timeout, network, etc) — skip this scan
+    return fixes;
+  }
+
+  // Check each issue to see if it's tracked in worker state
+  for (const issue of issuesWithLabel) {
+    const issueIdStr = String(issue.iid);
+
+    // Check if this issue is tracked
+    const isTracked = worker.active && worker.issueId === issueIdStr;
+
+    if (!isTracked) {
+      // Orphaned label: issue has active label but no worker tracking it
+      const fix: HealthFix = {
+        issue: {
+          type: "orphaned_label",
+          severity: "critical",
+          project: project.name,
+          groupId,
+          role,
+          issueId: issueIdStr,
+          expectedLabel: queueLabel,
+          actualLabel: activeLabel,
+          message: `Issue #${issue.iid} has "${activeLabel}" label but no ${role.toUpperCase()} worker is tracking it`,
+        },
+        fixed: false,
+      };
+
+      if (autoFix) {
+        try {
+          await provider.transitionLabel(issue.iid, activeLabel, queueLabel);
+          fix.fixed = true;
+          fix.labelReverted = `${activeLabel} → ${queueLabel}`;
+        } catch {
+          fix.labelRevertFailed = true;
+        }
+      }
+
+      fixes.push(fix);
+    }
+  }
+
+  return fixes;
+}

lib/services/heartbeat.ts

@@ -15,7 +15,7 @@ import fs from "node:fs";
 import path from "node:path";
 import { readProjects } from "../projects.js";
 import { log as auditLog } from "../audit.js";
-import { checkWorkerHealth, fetchGatewaySessions, type SessionLookup } from "./health.js";
+import { checkWorkerHealth, scanOrphanedLabels, fetchGatewaySessions, type SessionLookup } from "./health.js";
 import { projectTick } from "./tick.js";
 import { createProvider } from "../providers/index.js";
 
@@ -307,7 +307,8 @@ async function performHealthPass(
   let fixedCount = 0;
 
   for (const role of ["dev", "qa"] as const) {
-    const fixes = await checkWorkerHealth({
+    // Check worker health (session liveness, label consistency, etc)
+    const healthFixes = await checkWorkerHealth({
       workspaceDir,
       groupId,
       project,
@@ -316,7 +317,18 @@ async function performHealthPass(
       autoFix: true,
       provider,
     });
-    fixedCount += fixes.filter((f) => f.fixed).length;
+    fixedCount += healthFixes.filter((f) => f.fixed).length;
+
+    // Scan for orphaned labels (active labels with no tracking worker)
+    const orphanFixes = await scanOrphanedLabels({
+      workspaceDir,
+      groupId,
+      project,
+      role,
+      autoFix: true,
+      provider,
+    });
+    fixedCount += orphanFixes.filter((f) => f.fixed).length;
   }
 
   return fixedCount;

lib/tools/health.ts

@@ -8,6 +8,7 @@
  *   - stuck_label: inactive but issue has Doing/Testing label
  *   - orphan_issue_id: inactive but issueId set
  *   - issue_gone: active but issue deleted/closed
+ *   - orphaned_label: active label but no worker tracking it (NEW)
  *
  * Read-only by default (surfaces issues). Pass fix=true to apply fixes.
  */
@@ -15,7 +16,7 @@ import { jsonResult } from "openclaw/plugin-sdk";
 import type { ToolContext } from "../types.js";
 import { readProjects, getProject } from "../projects.js";
 import { log as auditLog } from "../audit.js";
-import { checkWorkerHealth, fetchGatewaySessions, type HealthFix } from "../services/health.js";
+import { checkWorkerHealth, scanOrphanedLabels, fetchGatewaySessions, type HealthFix } from "../services/health.js";
 import { requireWorkspaceDir, resolveProvider } from "../tool-helpers.js";
 
 export function createHealthTool() {
@@ -51,7 +52,8 @@ export function createHealthTool() {
         const { provider } = await resolveProvider(project);
 
         for (const role of ["dev", "qa"] as const) {
-          const fixes = await checkWorkerHealth({
+          // Worker health check (session liveness, label consistency, etc)
+          const healthFixes = await checkWorkerHealth({
             workspaceDir,
             groupId: pid,
             project,
@@ -60,7 +62,18 @@ export function createHealthTool() {
             autoFix: fix,
             provider,
           });
-          issues.push(...fixes.map((f) => ({ ...f, project: project.name, role })));
+          issues.push(...healthFixes.map((f) => ({ ...f, project: project.name, role })));
+
+          // Orphaned label scan (active labels with no tracking worker)
+          const orphanFixes = await scanOrphanedLabels({
+            workspaceDir,
+            groupId: pid,
+            project,
+            role,
+            autoFix: fix,
+            provider,
+          });
+          issues.push(...orphanFixes.map((f) => ({ ...f, project: project.name, role })));
         }
       }