fix(sync): harden incremental observability and periodic reconciliation

.github/workflows/deploy.yaml

@@ -231,9 +231,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build macOS distributables
         run: bun run make:macos
@@ -272,9 +273,10 @@ jobs:
         run: bun install --frozen-lockfile
 
       - name: Rebuild native modules
-        run: npm rebuild
+        run: npm rebuild --ignore-scripts
         env:
           HUSKY: "0"
+          HUSKY_SKIP_INSTALL: "1"
 
       - name: Build Windows distributables
         run: bun run make -- --platform win32

api/Dockerfile

@@ -91,7 +91,7 @@ COPY --from=build /app/dalpuri/generated/ ./dalpuri/generated/
 COPY --from=deps /app/node_modules/ ./node_modules/
 
 # Ensure pdfmake Roboto fonts are present at runtime for PDF generation.
-COPY --from=build /app/node_modules/pdfmake/build/fonts/ ./node_modules/pdfmake/build/fonts/
+COPY --from=build /app/api/node_modules/pdfmake/build/fonts/ ./node_modules/pdfmake/build/fonts/
 
 ENV NODE_ENV=production
 

api/kubernetes/worker-deployment.yaml

@@ -20,6 +20,11 @@ spec:
           env:
             - name: MANAGER_SOCKET_URL
               value: "http://optima-api.optima.svc.cluster.local:8671"
+            - name: API_DATABASE_URL
+              valueFrom:
+                secretKeyRef:
+                  name: api-env-secret
+                  key: DATABASE_URL
           envFrom:
             - secretRef:
                 name: api-env-secret

api/src/modules/workers/dalpuri-sync.ts

@@ -1,5 +1,6 @@
 import { Socket } from "socket.io-client";
 import { executeFullDalpuriSync, executeForcedIncrementalDalpuriSync } from "dalpuri";
+import { prisma } from "../../constants";
 
 /**
  * Execute a full sync from Dalpuri (ConnectWise) to the API database.
@@ -14,5 +15,53 @@ export async function executeFullSync(_workerSocket: Socket): Promise<void> {
  * Called every 5 seconds via PgBoss from the API process interval.
  */
 export async function executeIncrementalSync(): Promise<void> {
-  return executeForcedIncrementalDalpuriSync();
+  let jobRunId: string | undefined;
+
+  try {
+    const run = await prisma.syncJobRun.create({
+      data: {
+        jobType: "INCREMENTAL_SYNC",
+        status: "RUNNING",
+        triggeredBy: "worker",
+        startedAt: new Date(),
+      },
+      select: { id: true },
+    });
+    jobRunId = run.id;
+  } catch (err) {
+    // Sync should still run even if tracking insert fails.
+    console.error("[sync] Failed to create incremental SyncJobRun", err);
+  }
+
+  try {
+    await executeForcedIncrementalDalpuriSync({ jobRunId });
+
+    if (jobRunId) {
+      await prisma.syncJobRun.update({
+        where: { id: jobRunId },
+        data: {
+          status: "COMPLETED",
+          completedAt: new Date(),
+        },
+      });
+    }
+  } catch (err) {
+    if (jobRunId) {
+      const errorSummary = err instanceof Error ? err.message : String(err);
+      await prisma.syncJobRun
+        .update({
+          where: { id: jobRunId },
+          data: {
+            status: "FAILED",
+            completedAt: new Date(),
+            errorSummary: errorSummary.slice(0, 2000),
+          },
+        })
+        .catch(() => {
+          // Best-effort update only.
+        });
+    }
+
+    throw err;
+  }
 }

dalpuri/src/sync.ts

@@ -75,6 +75,43 @@ type DeleteResult = {
 
 let incrementalDeleteStepIndex = 0;
 
+const CRITICAL_INCREMENTAL_RECONCILE_TABLES = new Set([
+  "Companies",
+  "Company Addresses",
+  "Contacts",
+]);
+
+const criticalFullSyncIntervalMinutes = Math.max(
+  1,
+  Number.parseInt(
+    process.env.DALPURI_CRITICAL_FULL_SYNC_INTERVAL_MINUTES ?? "60",
+    10
+  ) || 60
+);
+
+const CRITICAL_FULL_SYNC_INTERVAL_MS =
+  criticalFullSyncIntervalMinutes * 60 * 1000;
+
+const lastCriticalFullSyncByStep = new Map<string, number>();
+
+const shouldForceCriticalFullSync = (
+  step: Step,
+  forceIncremental: boolean
+): boolean => {
+  if (!forceIncremental) return false;
+  if (!CRITICAL_INCREMENTAL_RECONCILE_TABLES.has(step.name)) return false;
+
+  const now = Date.now();
+  const last = lastCriticalFullSyncByStep.get(step.name) ?? 0;
+
+  if (now - last < CRITICAL_FULL_SYNC_INTERVAL_MS) {
+    return false;
+  }
+
+  lastCriticalFullSyncByStep.set(step.name, now);
+  return true;
+};
+
 const parseEnvFile = (path: string): Record<string, string> => {
   const envData = readFileSync(path, "utf8");
   const out: Record<string, string> = {};
@@ -107,6 +144,20 @@ const resolveApiDatabaseUrl = (): string => {
   if (process.env.OPTIMA_API_DATABASE_URL)
     return process.env.OPTIMA_API_DATABASE_URL;
 
+  // Worker/runtime fallback:
+  // In Kubernetes we often provide CW via CW_DATABASE_URL and API Postgres via
+  // DATABASE_URL. Only use DATABASE_URL as API when we can safely infer that.
+  if (process.env.CW_DATABASE_URL && process.env.DATABASE_URL) {
+    return process.env.DATABASE_URL;
+  }
+
+  if (
+    process.env.DATABASE_URL &&
+    /^(postgres|postgresql):\/\//i.test(process.env.DATABASE_URL)
+  ) {
+    return process.env.DATABASE_URL;
+  }
+
   const candidates = [
     resolve(import.meta.dir, "../../api/.env"),
     resolve(process.cwd(), "../api/.env"),
@@ -1757,19 +1808,35 @@ export const executeFullDalpuriSync = async (options?: {
         step,
         forceIncremental
       );
+      const forceCriticalFullSync = shouldForceCriticalFullSync(
+        step,
+        forceIncremental
+      );
+      const effectiveDecision = forceCriticalFullSync
+        ? ({ mode: "full", differences: decision.differences } as SmartSyncDecision)
+        : decision;
+
+      if (forceCriticalFullSync) {
+        console.log(
+          `  [smart-sync][forced-full] ${step.name}: forcing periodic full reconciliation every ${criticalFullSyncIntervalMinutes}m`
+        );
+      }
+
       const sourceIdsFilter =
-        decision.mode === "incremental" ? decision.sourceIds : undefined;
+        effectiveDecision.mode === "incremental"
+          ? effectiveDecision.sourceIds
+          : undefined;
       console.log(
         `  [smart-sync]${forceIncremental ? "[forced]" : ""} mode=${
-          decision.mode
+          effectiveDecision.mode
         }${
-          decision.mode === "incremental"
+          effectiveDecision.mode === "incremental"
-            ? ` (${decision.sourceIds.length} ids)`
+            ? ` (${effectiveDecision.sourceIds.length} ids)`
             : ""
         }`
       );
       if (logAllDifferences) {
-        logAllSmartSyncDifferences(step, decision.differences);
+        logAllSmartSyncDifferences(step, effectiveDecision.differences);
       }
       const result = await syncStep(
         cwPrisma,
@@ -1791,7 +1858,7 @@ export const executeFullDalpuriSync = async (options?: {
 
       await writeStepLog(
         step.name,
-        decision.mode,
+        effectiveDecision.mode,
         result,
         { deleted: 0, failed: 0 },
         Date.now() - stepStart