fix: otel warning during tail sampling buffer replay

[cyberksh]

When TailSamplingProcessor.push_buffer() replays buffered spans, it was calling on_start for spans that had already ended. This caused wrapped processors like DirectBaggageAttributesSpanProcessor to call span.set_attributes() on ended spans, triggering OpenTelemetry warnings.

This fix tracks which spans have already ended and skips the on_start call for them, since setting attributes on ended spans has no effect anyway and the spans are still properly exported via on_end.

[codecov]

Codecov Report

✅ All modified and coverable lines are covered by tests.

📢 Thoughts on this report? Let us know!

[cyberksh]

Reproducer:

"""
Reproducer for logfire tail sampling "Setting attribute on ended span" warning.

The warning occurs when:
1. Tail sampling buffers spans (not immediately sampled)
2. A later event triggers sampling (error, duration threshold)
3. push_buffer() calls on_start for already-ended spans

Run this script and make requests to trigger the warning.
"""

import asyncio
import logging
import time

# Configure logging BEFORE logfire to see warnings
logging.basicConfig(
    level=logging.DEBUG,
    format="%(levelname)s | %(name)s:%(funcName)s:%(lineno)d | %(message)s",
)

import logfire
from fastapi import FastAPI
import uvicorn


def tail_sampling_function(span_info: logfire.sampling.TailSamplingSpanInfo) -> float:
    """
    Tail sampling that triggers on errors or long duration.
    Most traces are buffered and discarded (rate=0.0).
    Only traces with errors or duration > 0.5s are sampled.
    """
    # Only sample if there's an error or duration > 0.5 seconds
    if span_info.level >= "error":
        return 1.0
    if span_info.duration > 0.5:
        return 1.0
    # Don't sample normal requests - they stay buffered then get discarded
    return 0.0


# Configure logfire with tail sampling
logfire.configure(
    service_name="reproducer",
    send_to_logfire=False,
    console=logfire.ConsoleOptions(),  # Enable console output to see traces
    sampling=logfire.SamplingOptions(tail=tail_sampling_function),
)

app = FastAPI()
logfire.instrument_fastapi(app)


@app.get("/fast")
async def fast_endpoint():
    """Fast endpoint - won't trigger sampling, no warning."""
    return {"status": "fast"}


@app.get("/slow")
async def slow_endpoint():
    """
    Slow endpoint - triggers sampling after child spans have ended.
    This WILL produce the warning because:
    1. Child spans are created and end quickly
    2. They get buffered
    3. After 0.6s, duration threshold is exceeded
    4. push_buffer() calls on_start for already-ended child spans
    """
    # Create some child spans that end before the sampling decision
    with logfire.span("child_span_1"):
        await asyncio.sleep(0.05)

    with logfire.span("child_span_2"):
        await asyncio.sleep(0.05)

    with logfire.span("child_span_3"):
        await asyncio.sleep(0.05)

    # Now wait to exceed duration threshold
    # This triggers sampling AFTER child spans have ended
    await asyncio.sleep(0.5)

    return {"status": "slow", "message": "Check logs for 'Setting attribute on ended span' warning"}


@app.get("/error")
async def error_endpoint():
    """
    Error endpoint - triggers sampling when error is logged.
    Similar to slow, but triggers on error level instead of duration.
    """
    with logfire.span("setup_span"):
        await asyncio.sleep(0.05)

    with logfire.span("processing_span"):
        await asyncio.sleep(0.05)

    # Log an error - this triggers sampling after child spans ended
    logfire.error("Something went wrong!")

    return {"status": "error logged"}


@app.get("/nested")
async def nested_endpoint():
    """
    Deeply nested spans - more child spans = more warnings.
    """

    async def do_work(depth: int):
        if depth <= 0:
            return
        with logfire.span(f"nested_level_{depth}"):
            await asyncio.sleep(0.02)
            await do_work(depth - 1)

    await do_work(5)

    # Trigger sampling after all nested spans ended
    await asyncio.sleep(0.5)

    return {"status": "nested complete"}


if __name__ == "__main__":
    print("""
Reproducer for "Setting attribute on ended span" warning.

Endpoints:
  GET /fast   - Fast request, no sampling, no warning
  GET /slow   - Slow request (0.6s), triggers sampling, PRODUCES WARNING
  GET /error  - Logs error, triggers sampling, PRODUCES WARNING
  GET /nested - Nested spans + slow, PRODUCES MULTIPLE WARNINGS

To reproduce:
  curl http://localhost:8000/slow

Watch the console for:
  WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
""")
    uvicorn.run(app, host="0.0.0.0", port=8000, log_level="debug")

python reproducer.py

Reproducer for "Setting attribute on ended span" warning.

Endpoints:
  GET /fast   - Fast request, no sampling, no warning
  GET /slow   - Slow request (0.6s), triggers sampling, PRODUCES WARNING
  GET /error  - Logs error, triggers sampling, PRODUCES WARNING
  GET /nested - Nested spans + slow, PRODUCES MULTIPLE WARNINGS

To reproduce:
  curl http://localhost:8000/slow

Watch the console for:
  WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.

INFO:     Started server process [3139581]
INFO:     Waiting for application startup.
INFO:     Application startup complete.
INFO:     Uvicorn running on http://0.0.0.0:8000 (Press CTRL+C to quit)
INFO:     127.0.0.1:42244 - "GET /slow HTTP/1.1" 200 OK
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
03:12:53.329 GET /error
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
03:12:53.436   Something went wrong!
INFO:     127.0.0.1:42254 - "GET /error HTTP/1.1" 200 OK
INFO:     127.0.0.1:38208 - "GET /nested HTTP/1.1" 200 OK
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
WARNING | opentelemetry.sdk.trace:set_attributes:850 | Setting attribute on ended span.
^CINFO:     Shutting down
INFO:     Waiting for application shutdown.
INFO:     Application shutdown complete.