fix(effort): per-role floor for --effort resolution + developer→xhigh

resolve_agent_effort returned '' for all agents in prod because empty
ORCH_AGENT_EFFORT_*= env vars clobber pydantic class-defaults, leaving no
non-empty floor to fall back to -> --effort never reached the Claude CLI.

Add a level-4 per-role floor in resolve_agent_effort (src/agents/launcher.py):
_agent_effort_floor reads the declared class-default of agent_effort_<agent>
(model_fields[...].default), which a present-but-empty env cannot override.
Floor applies only when levels 1-3 are empty and BEFORE validation, so a typo
(non-empty) still drops to '' (never-break ORCH-41) and explicit env/override
still wins (priority preserved). config.py: agent_effort_developer high->xhigh
(single source of truth; floor follows automatically).

Refs: ORCH-081

Co-Authored-By: Claude Opus 4.7 <noreply@anthropic.com>

tests/test_resolve_agent_effort.py

@@ -26,13 +26,22 @@ from src.projects import ProjectConfig, reload_projects
 ORCH_PLANE_ID = "8da6aa25-a60e-44d6-a1e2-d8ae59aa7d6a"
 
 
+# ORCH-081/ORCH-52h: canonical effort per role (developer upgraded high -> xhigh).
+CANON_EFFORT = {
+    "analyst": "high",
+    "architect": "high",
+    "developer": "xhigh",
+    "reviewer": "high",
+    "tester": "medium",
+    "deployer": "medium",
+}
+
+
 @pytest.fixture(autouse=True)
 def _clean_settings(monkeypatch):
     monkeypatch.setattr(settings, "agent_effort_default", "high")
-    for a in ("analyst", "architect", "developer", "reviewer"):
-        monkeypatch.setattr(settings, f"agent_effort_{a}", "high")
-    for a in ("tester", "deployer"):
-        monkeypatch.setattr(settings, f"agent_effort_{a}", "medium")
+    for a, e in CANON_EFFORT.items():
+        monkeypatch.setattr(settings, f"agent_effort_{a}", e)
     monkeypatch.setattr(P.settings, "projects_json", "")
     reload_projects()
     yield
@@ -50,19 +59,40 @@ def _install_registry(monkeypatch, agent_efforts):
     monkeypatch.setattr(P, "_BY_REPO", {p.repo: p for p in reg})
 
 
-# ---- default split ----------------------------------------------------------
+# ---- TC-01: canonical defaults (AC-1 / FR-4) --------------------------------
 def test_default_split():
-    assert resolve_agent_effort("developer") == "high"
+    assert resolve_agent_effort("developer") == "xhigh"
     assert resolve_agent_effort("architect") == "high"
     assert resolve_agent_effort("tester") == "medium"
     assert resolve_agent_effort("deployer") == "medium"
 
 
-# ---- level 4: nothing -> "" -------------------------------------------------
-def test_no_config_returns_empty(monkeypatch):
+@pytest.mark.parametrize("agent,expected", list(CANON_EFFORT.items()))
+def test_canonical_effort_all_roles(agent, expected):
+    assert resolve_agent_effort(agent) == expected
+
+
+# ---- TC-02: empty env -> per-role floor (variant c, AC-2) -------------------
+@pytest.mark.parametrize("agent,expected", list(CANON_EFFORT.items()))
+def test_empty_env_falls_back_to_per_role_floor(monkeypatch, agent, expected):
+    """Models the prod bug: ORCH_AGENT_EFFORT_*= present-but-empty -> every level
+    resolves to '' on the instance; the per-role floor (config class-default) must
+    still yield the canonical level (NOT '')."""
+    monkeypatch.setattr(settings, "agent_effort_default", "")
+    for a in CANON_EFFORT:
+        monkeypatch.setattr(settings, f"agent_effort_{a}", "")
+    result = resolve_agent_effort(agent)
+    assert result == expected
+    assert result != ""
+
+
+# ---- unknown agent floor degrades to default (high), never '' ---------------
+def test_empty_env_unknown_agent_floor_is_default(monkeypatch):
     monkeypatch.setattr(settings, "agent_effort_default", "")
     monkeypatch.setattr(settings, "agent_effort_tester", "")
-    assert resolve_agent_effort("tester") == ""
+    # An agent with no agent_effort_<name> field falls back to the
+    # agent_effort_default class-default (high), a safe non-empty floor.
+    assert resolve_agent_effort("nonexistent_role") == "high"
 
 
 # ---- level 2: per-agent env beats default -----------------------------------
@@ -103,6 +133,45 @@ def test_all_valid_efforts_pass(monkeypatch):
         assert resolve_agent_effort("developer") == e
 
 
+# ---- TC-03: floor does NOT mask a typo (FR-3 / AC-5) ------------------------
+def test_floor_does_not_mask_typo(monkeypatch):
+    """An explicit invalid value is non-empty, so the floor is NOT applied: the
+    value is validated and dropped to '' (never-break ORCH-41), even though the
+    developer floor (xhigh) exists."""
+    monkeypatch.setattr(settings, "agent_effort_default", "")
+    monkeypatch.setattr(settings, "agent_effort_developer", "turbo")
+    assert resolve_agent_effort("developer") == ""
+
+
+# ---- TC-04: priority preserved — explicit config beats floor (FR-2) ---------
+def test_explicit_env_beats_floor(monkeypatch):
+    """Operator may deliberately downgrade developer to high; the explicit
+    non-empty env wins over the xhigh floor."""
+    monkeypatch.setattr(settings, "agent_effort_developer", "high")
+    assert resolve_agent_effort("developer") == "high"
+
+
+def test_default_beats_floor(monkeypatch):
+    """A non-empty global default wins over the per-role floor (floor is strictly
+    below default): default=max with empty per-agent -> max, not the xhigh floor."""
+    monkeypatch.setattr(settings, "agent_effort_developer", "")
+    monkeypatch.setattr(settings, "agent_effort_default", "max")
+    assert resolve_agent_effort("developer") == "max"
+
+
+def test_project_override_beats_floor(monkeypatch):
+    monkeypatch.setattr(settings, "agent_effort_developer", "")
+    _install_registry(monkeypatch, {"developer": "high"})
+    assert resolve_agent_effort("developer", ORCH_PLANE_ID) == "high"
+
+
+# ---- TC-05: xhigh is a valid effort (FR-5) ----------------------------------
+def test_xhigh_is_valid():
+    assert "xhigh" in VALID_EFFORTS
+    # developer canonical xhigh resolves (is not dropped by validation)
+    assert resolve_agent_effort("developer") == "xhigh"
+
+
 # ---- flag assembly (mirror of launcher cmd construction) --------------------
 def _build_flags(model, effort, fb):
     model_flag = f"--model {model} " if model else ""
@@ -111,6 +180,7 @@ def _build_flags(model, effort, fb):
     return f"{model_flag}{effort_flag}{fb_flag}"
 
 
+# ---- TC-06: flag assembly (AC-3) --------------------------------------------
 def test_flags_present_when_configured(monkeypatch):
     monkeypatch.setattr(settings, "agent_fallback_model", "claude-sonnet-4-6")
     model = resolve_agent_model("developer")
@@ -118,21 +188,32 @@ def test_flags_present_when_configured(monkeypatch):
     fb = settings.agent_fallback_model
     flags = _build_flags(model, effort, fb)
     assert "--model claude-opus-4-8 " in flags
-    assert "--effort high " in flags
+    assert "--effort xhigh " in flags
     assert "--fallback-model claude-sonnet-4-6 " in flags
 
 
-def test_flags_absent_when_empty(monkeypatch):
+def test_flags_effort_per_role(monkeypatch):
+    """developer -> --effort xhigh; tester -> --effort medium (mirrors _spawn)."""
+    assert "--effort xhigh " in _build_flags("", resolve_agent_effort("developer"), "")
+    assert "--effort medium " in _build_flags("", resolve_agent_effort("tester"), "")
+
+
+def test_flags_absent_when_effort_empty():
+    """When the resolved effort is empty, --effort is omitted entirely. Mirrors the
+    `f"--effort {effort} " if effort else ""` branch in _spawn (AC-3 negative case)."""
+    flags = _build_flags("", "", "")
+    assert flags == ""
+    assert "--effort" not in flags
+
+
+def test_flags_absent_when_model_empty(monkeypatch):
     monkeypatch.setattr(settings, "agent_model_default", "")
     monkeypatch.setattr(settings, "agent_model_developer", "")
-    monkeypatch.setattr(settings, "agent_effort_default", "")
-    monkeypatch.setattr(settings, "agent_effort_developer", "")
     monkeypatch.setattr(settings, "agent_fallback_model", "")
     model = resolve_agent_model("developer")
-    effort = resolve_agent_effort("developer")
     fb = settings.agent_fallback_model
-    flags = _build_flags(model, effort, fb)
+    flags = _build_flags(model, "", fb)
     assert flags == ""
     assert "--model" not in flags
-    assert "--effort" not in flags
+    assert "--fallback-model" not in flags
     assert "--fallback-model" not in flags