test(e2e): optimize global setup and fix hanging issues

docs/plans/current_spec.md

@@ -89,6 +89,7 @@ npx playwright test
 - [x] Modify playwright.config.js to comment out security projects
 - [x] Remove security-tests dependency from browser projects
 - [x] Fix Go cache path in e2e-tests.yml workflow
+- [x] Optimize global-setup.ts to prevent hanging on emergency reset
 - [ ] Commit with clear diagnostic message
 - [ ] Trigger CI run
 - [ ] Analyze results and document findings
@@ -119,3 +120,42 @@ Restore cache failed: Dependencies file is not found in /home/runner/work/Charon
 ```
 
 **Impact**: The Go module cache will now properly restore, speeding up the build process by ~30-60 seconds per run.
+
+### Global Setup Optimization (Hanging Prevention)
+
+**Issue**: Shards were hanging after the "Skipping authenticated security reset" message during global-setup.ts execution.
+
+**Root Cause**:
+1. Emergency security reset API calls had no timeout - could hang indefinitely
+2. 2-second propagation delay after each reset (called twice = 4+ seconds)
+3. Pre-auth reset was being attempted even on fresh containers where it's unnecessary
+
+**Fixes Applied**:
+1. **Added 5-second timeout** to emergency reset API calls to prevent indefinite hangs
+2. **Reduced propagation delay** from 2000ms to 500ms (fresh containers don't need long waits)
+3. **Skip pre-auth reset in CI** when using default test token (fresh containers start clean)
+
+**Before**:
+```typescript
+const response = await requestContext.post('/api/v1/emergency/security-reset', {
+  headers: { 'X-Emergency-Token': emergencyToken },
+  // No timeout - could hang forever
+});
+// ...
+await new Promise(resolve => setTimeout(resolve, 2000)); // 2s wait
+```
+
+**After**:
+```typescript
+const response = await requestContext.post('/api/v1/emergency/security-reset', {
+  headers: { 'X-Emergency-Token': emergencyToken },
+  timeout: 5000, // 5s timeout prevents hanging
+});
+// ...
+await new Promise(resolve => setTimeout(resolve, 500)); // 500ms wait
+```
+
+**Impact**:
+- ✅ Prevents shards from hanging on global-setup
+- ✅ Reduces global-setup time by ~3-4 seconds per shard
+- ✅ Skips unnecessary emergency reset on fresh CI containers

tests/global-setup.ts

@@ -28,13 +28,18 @@ async function globalSetup(): Promise<void> {
   // Pre-auth security reset attempt (crash protection failsafe)
   // This attempts to disable security modules BEFORE auth, in case a previous run crashed
   // with security enabled blocking the auth endpoint.
-  const preAuthContext = await request.newContext({ baseURL });
-  try {
-    await emergencySecurityReset(preAuthContext);
-  } catch (e) {
-    console.log('Pre-auth security reset skipped (may require auth)');
+  // SKIPPED in CI when CHARON_EMERGENCY_TOKEN is not set - fresh containers don't need reset
+  if (process.env.CHARON_EMERGENCY_TOKEN && process.env.CHARON_EMERGENCY_TOKEN !== 'test-emergency-token-for-e2e-32chars') {
+    const preAuthContext = await request.newContext({ baseURL });
+    try {
+      await emergencySecurityReset(preAuthContext);
+    } catch (e) {
+      console.log('⏭️  Pre-auth security reset skipped (may require auth)');
+    }
+    await preAuthContext.dispose();
+  } else {
+    console.log('⏭️  Pre-auth security reset skipped (fresh container, no custom token)');
   }
-  await preAuthContext.dispose();
 
   // Create a request context
   const requestContext = await request.newContext({
@@ -135,6 +140,7 @@ async function emergencySecurityReset(requestContext: APIRequestContext): Promis
       headers: {
         'X-Emergency-Token': emergencyToken,
       },
+      timeout: 5000, // 5s timeout to prevent hanging
     });
 
     if (!response.ok()) {
@@ -146,15 +152,15 @@ async function emergencySecurityReset(requestContext: APIRequestContext): Promis
     const result = await response.json();
     console.log('  ✅ Emergency reset successful');
     console.log(`  ✅ Disabled modules: ${result.disabled_modules?.join(', ')}`);
+
+    // Reduced wait time - fresh containers don't need long propagation
+    console.log('  ⏳ Waiting for security reset to propagate...');
+    await new Promise(resolve => setTimeout(resolve, 500));
   } catch (e) {
     console.error(`  ❌ Emergency reset error: ${e}`);
     throw e;
   }
 
-  // Wait for settings to propagate
-  console.log('  ⏳ Waiting for security reset to propagate...');
-  await new Promise(resolve => setTimeout(resolve, 2000));
-
   console.log('  ✅ Security reset complete');
 }