fix: Persist credentials across container and orchestrator restarts

Previously, the agent would clear credentials on ANY heartbeat failure,
causing infinite re-registration loops when:
- Agent container was updated while orchestrator was running
- Orchestrator was restarted while agent was running

Changes:
- Add HeartbeatStatus enum and HeartbeatResult dataclass
- Modify heartbeat() to return status info instead of just bool
- Only clear credentials on 401/403 (AUTH_FAILED)
- Keep credentials on transient errors (NETWORK_ERROR, SERVER_ERROR)
- Handle AUTH_FAILED in heartbeat_loop() for mid-session invalidation

Scenarios now handled:
- Agent restart: keeps creds, retries until orchestrator responds
- Orchestrator restart: keeps creds, retries with backoff
- Admin deletes agent: clears creds, breaks out for re-registration

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

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

app/agent.py

@@ -5,7 +5,13 @@ import platform
 import random
 from typing import Optional
 
-from app.clients.orchestrator_client import CircuitBreakerOpen, EventLevel, OrchestratorClient
+from app.clients.orchestrator_client import (
+    CircuitBreakerOpen,
+    EventLevel,
+    HeartbeatResult,
+    HeartbeatStatus,
+    OrchestratorClient,
+)
 from app.config import Settings, get_settings
 from app.utils.logger import get_logger
 
@@ -73,16 +79,37 @@ class Agent:
             )
 
             # Verify credentials still work by sending heartbeat
-            if await self.client.heartbeat():
+            result = await self.client.heartbeat()
+
+            if result.status == HeartbeatStatus.SUCCESS:
                 logger.info("credentials_verified")
                 # Retry any pending results from previous session
                 await self.client.retry_pending_results()
                 return True
-            else:
-                # Credentials may be invalid, clear and re-register
-                logger.warning("credentials_invalid_reregistering")
+
+            elif result.status == HeartbeatStatus.AUTH_FAILED:
+                # Only clear credentials on explicit auth failure (401/403)
+                logger.warning("credentials_invalid_clearing", reason=result.message)
                 self.client.clear_credentials()
                 self._registered = False
+                # Fall through to registration
+
+            elif result.status == HeartbeatStatus.NOT_REGISTERED:
+                # Should not happen if load_credentials succeeded, but handle it
+                logger.warning("credentials_not_registered_state")
+                self._registered = False
+                # Fall through to registration
+
+            elif result.status in (HeartbeatStatus.SERVER_ERROR, HeartbeatStatus.NETWORK_ERROR):
+                # Transient error - keep credentials, retry later
+                # Do NOT retry_pending_results here - orchestrator is unhealthy
+                # Main heartbeat loop will handle retries with backoff
+                logger.warning(
+                    "credentials_verification_transient_error",
+                    status=result.status.value,
+                    message=result.message,
+                )
+                return True
 
         # Check if we have registration token or can do legacy registration
         if not self.settings.registration_token and not self.settings.tenant_id:
@@ -169,31 +196,35 @@ class Agent:
         backoff_multiplier = 1.0
 
         while not self._shutdown_event.is_set():
-            try:
-                success = await self.client.heartbeat()
+            result = await self.client.heartbeat()
 
-                if success:
-                    consecutive_failures = 0
-                    backoff_multiplier = 1.0
-                    logger.debug("heartbeat_sent", agent_id=self.client.agent_id)
-                else:
-                    consecutive_failures += 1
-                    backoff_multiplier = min(backoff_multiplier * 1.5, 4.0)
-                    logger.warning(
-                        "heartbeat_failed",
-                        consecutive_failures=consecutive_failures,
-                    )
+            if result.status == HeartbeatStatus.SUCCESS:
+                consecutive_failures = 0
+                backoff_multiplier = 1.0
+                logger.debug("heartbeat_sent", agent_id=self.client.agent_id)
 
-            except CircuitBreakerOpen:
-                logger.warning("heartbeat_circuit_breaker_open")
-                backoff_multiplier = 4.0  # Max backoff during circuit break
+            elif result.status == HeartbeatStatus.AUTH_FAILED:
+                # Credentials truly invalid (e.g., agent deleted in orchestrator)
+                logger.warning(
+                    "heartbeat_auth_failed_clearing_credentials",
+                    message=result.message,
+                )
+                self.client.clear_credentials()
+                self._registered = False  # Outer loop will re-run register()
+                consecutive_failures = 0
+                backoff_multiplier = 1.0
+                # Break out of heartbeat loop to trigger re-registration
+                break
 
-            except Exception as e:
+            else:
+                # NETWORK_ERROR / SERVER_ERROR / NOT_REGISTERED
+                # Transient issues - keep credentials, just backoff
                 consecutive_failures += 1
                 backoff_multiplier = min(backoff_multiplier * 1.5, 4.0)
-                logger.error(
-                    "heartbeat_error",
-                    error=str(e),
+                logger.warning(
+                    "heartbeat_failed_transient",
+                    status=result.status.value,
+                    message=result.message,
                     consecutive_failures=consecutive_failures,
                 )
 

app/clients/orchestrator_client.py

@@ -52,6 +52,24 @@ class CircuitBreakerOpen(Exception):
     pass
 
 
+class HeartbeatStatus(str, Enum):
+    """Status of a heartbeat attempt."""
+
+    SUCCESS = "success"
+    AUTH_FAILED = "auth_failed"  # 401/403 - credentials invalid
+    SERVER_ERROR = "server_error"  # 5xx - transient, retry
+    NETWORK_ERROR = "network_error"  # Connection failed, timeout
+    NOT_REGISTERED = "not_registered"  # No agent_id/secret set
+
+
+@dataclass
+class HeartbeatResult:
+    """Result of a heartbeat attempt with status and optional message."""
+
+    status: HeartbeatStatus
+    message: str = ""
+
+
 class OrchestratorClient:
     """Async client for Orchestrator REST API.
 
@@ -377,15 +395,20 @@ class OrchestratorClient:
             )
             return self._agent_id, self._token, self._tenant_id
 
-    async def heartbeat(self) -> bool:
+    async def heartbeat(self) -> HeartbeatResult:
         """Send heartbeat to orchestrator.
 
         Returns:
-            True if heartbeat was acknowledged
+            HeartbeatResult with status indicating success or failure type.
+            - SUCCESS: Heartbeat acknowledged (200)
+            - AUTH_FAILED: Credentials invalid (401/403)
+            - SERVER_ERROR: Server issue (5xx), transient
+            - NETWORK_ERROR: Connection failed, transient
+            - NOT_REGISTERED: No agent_id set
         """
         if not self._agent_id:
             logger.warning("heartbeat_skipped", reason="not_registered")
-            return False
+            return HeartbeatResult(HeartbeatStatus.NOT_REGISTERED, "No agent_id set")
 
         try:
             response = await self._request_with_retry(
@@ -393,10 +416,32 @@ class OrchestratorClient:
                 f"{self.API_PREFIX}/agents/{self._agent_id}/heartbeat",
                 max_retries=1,  # Don't retry too aggressively for heartbeats
             )
-            return response.status_code == 200
-        except (httpx.HTTPError, CircuitBreakerOpen) as e:
-            logger.warning("heartbeat_failed", error=str(e))
-            return False
+
+            if response.status_code == 200:
+                return HeartbeatResult(HeartbeatStatus.SUCCESS)
+            elif response.status_code in (401, 403):
+                msg = f"HTTP {response.status_code}: {response.text[:200]}"
+                logger.warning("heartbeat_auth_failed", status_code=response.status_code)
+                return HeartbeatResult(HeartbeatStatus.AUTH_FAILED, msg)
+            elif response.status_code >= 500:
+                msg = f"HTTP {response.status_code}: {response.text[:200]}"
+                logger.warning("heartbeat_server_error", status_code=response.status_code)
+                return HeartbeatResult(HeartbeatStatus.SERVER_ERROR, msg)
+            else:
+                # 4xx other than 401/403 - treat as auth failure
+                msg = f"HTTP {response.status_code}: {response.text[:200]}"
+                logger.warning("heartbeat_client_error", status_code=response.status_code)
+                return HeartbeatResult(HeartbeatStatus.AUTH_FAILED, msg)
+
+        except (httpx.ConnectError, httpx.TimeoutException) as e:
+            logger.warning("heartbeat_network_error", error=str(e))
+            return HeartbeatResult(HeartbeatStatus.NETWORK_ERROR, str(e))
+        except httpx.HTTPError as e:
+            logger.warning("heartbeat_http_error", error=str(e))
+            return HeartbeatResult(HeartbeatStatus.NETWORK_ERROR, str(e))
+        except CircuitBreakerOpen:
+            logger.warning("heartbeat_circuit_breaker_open")
+            return HeartbeatResult(HeartbeatStatus.NETWORK_ERROR, "Circuit breaker open")
 
     async def fetch_next_task(self) -> Optional[Task]:
         """Fetch the next available task for this agent.