fix: handle broken codecarbon installations in CI

- Catch non-ImportError exceptions from broken codecarbon installs
  (e.g., missing nordic_emissions.json) and clean up sys.modules
- Widen except clause in _display_carbon_tracking_status to catch
  all exceptions, not just ImportError
- Disable carbon tracking by default in test settings
- Pass no_environmental_impact=True in restart test subprocess
- Add global pytest timeout (300s) to prevent indefinite hangs

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

Author: bpiwowar

pyproject.toml

@@ -162,6 +162,7 @@ log_cli_format = "[%(levelname)s] %(asctime)s %(name)s [%(process)d/%(threadName
 log_date_format = "%H:%M:%S"
 log_cli_date_format = "%H:%M:%S"
 addopts = "--order-dependencies --ignore-unknown-dependency"
+timeout = 300
 
 markers = [
     # Core foundation (no dependencies)

src/experimaestro/carbon/__init__.py

@@ -72,6 +72,16 @@ def _is_codecarbon_available() -> bool:
         import codecarbon  # noqa: F401
     except ImportError:
         return False
+    except Exception:
+        # Handle broken installations (e.g., missing data files like
+        # nordic_emissions.json). Clean up partially-loaded modules to prevent
+        # subsequent imports from using a corrupted module object.
+        import sys
+
+        for key in list(sys.modules):
+            if key == "codecarbon" or key.startswith("codecarbon."):
+                del sys.modules[key]
+        return False
 
     system = platform.system()
     machine = platform.machine()

src/experimaestro/scheduler/experiment.py

@@ -344,8 +344,8 @@ def _display_carbon_tracking_status(self) -> None:
                         "[Carbon Tracking] Disabled - %s",
                         reason or "Not available",
                     )
-        except ImportError:
-            # Carbon module not available at all
+        except Exception:
+            # Carbon module not available or broken installation
             if carbon_settings.warn_if_unavailable:
                 self._show_carbon_warning(None)
             else:

src/experimaestro/settings.py

@@ -1,4 +1,4 @@
-import os
+import sys
 from omegaconf import OmegaConf, SCMode
 from dataclasses import field, dataclass
 from functools import lru_cache
@@ -134,8 +134,10 @@ class Settings:
 
 @lru_cache()
 def get_settings(path: Optional[Path] = None) -> Settings:
-    if "PYTEST_CURRENT_TEST" in os.environ:
-        return Settings()
+    if getattr(sys, "_called_from_test", False):
+        settings = Settings()
+        settings.carbon.enabled = False
+        return settings
     else:
         schema = OmegaConf.structured(Settings)
 

src/experimaestro/tests/restart_main.py

@@ -7,5 +7,5 @@
     wspath, module, functionname = sys.argv[1:]
     print("Importing", module)
     f = getattr(importlib.import_module(module), functionname)
-    with experiment(wspath, "restart") as xp:
+    with experiment(wspath, "restart", no_environmental_impact=True) as xp:
         f(xp)