test(server): reap orphaned test browsers before spawn

Pre-kill BrowserOS processes whose --user-data-dir path contains the
browseros-test- prefix before each spawnBrowser, and in the test:cleanup
hook. This prevents a crashed prior test run from leaving a headless
BrowserOS attached to a stale port, without touching the developer's
regular BrowserOS.app instance (its user-data-dir is
~/Library/Application Support/BrowserOS, which does not match).

packages/browseros-agent/apps/server/tests/__helpers__/browser.ts

@@ -6,9 +6,11 @@
  * Use setup.ts:ensureBrowserOS() for the full test environment.
  */
 import type { ChildProcess } from 'node:child_process'
-import { spawn } from 'node:child_process'
+import { spawn, spawnSync } from 'node:child_process'
 import { rmSync } from 'node:fs'
 
+const TEST_USER_DATA_PREFIX = 'browseros-test-'
+
 export interface BrowserConfig {
   cdpPort: number
   serverPort: number
@@ -58,6 +60,16 @@ export function getBrowserState(): BrowserState | null {
   return browserState
 }
 
+function killOrphanedTestBrowsers(): void {
+  // Matches only BrowserOS processes launched with a test user-data-dir
+  // (e.g., /var/folders/.../browseros-test-XXXX). Never matches a dev
+  // BrowserOS run from ~/Library/Application Support/BrowserOS.
+  const result = spawnSync('pkill', ['-9', '-f', TEST_USER_DATA_PREFIX])
+  if (result.status === 0) {
+    console.log('Killed orphaned test browsers from a previous run')
+  }
+}
+
 export async function spawnBrowser(
   config: BrowserConfig,
 ): Promise<BrowserState> {
@@ -73,6 +85,8 @@ export async function spawnBrowser(
     await killBrowser()
   }
 
+  killOrphanedTestBrowsers()
+
   console.log(`Starting BrowserOS on CDP port ${config.cdpPort}...`)
   const browserProcess = spawn(
     config.binaryPath,

packages/browseros-agent/apps/server/tests/__helpers__/cleanup.sh

@@ -20,6 +20,14 @@ for port in $CDP_PORT $SERVER_PORT $EXTENSION_PORT; do
   fi
 done
 
+# Kill orphaned test browser processes (matches only BrowserOS launched with
+# a test user-data-dir — never the user's dev BrowserOS)
+orphan_pids=$(pgrep -f 'browseros-test-' 2>/dev/null || true)
+if [ -n "$orphan_pids" ]; then
+  echo "  Killing orphaned test browser processes: $(echo "$orphan_pids" | tr '\n' ' ')"
+  echo "$orphan_pids" | xargs kill -9 2>/dev/null || true
+fi
+
 # Clean up orphaned temp directories (created by browser.ts)
 # Uses $TMPDIR which matches Node's os.tmpdir()
 TEMP_DIR="${TMPDIR:-/tmp}"