Fix: Orchestrator timeout and exception handling

shelfmark/download/orchestrator.py

@@ -56,9 +56,11 @@
 
 # Stall detection - track last activity time per download
 _last_activity: Dict[str, float] = {}
+_last_progress_value: Dict[str, float] = {}
 # De-duplicate status updates (keep-alive updates shouldn't spam clients)
 _last_status_event: Dict[str, Tuple[str, Optional[str]]] = {}
 STALL_TIMEOUT = 300  # 5 minutes without progress/status update = stalled
+COORDINATOR_LOOP_ERROR_RETRY_DELAY = 1.0
 
 def _is_plain_email_address(value: str) -> bool:
     parsed = parseaddr(value or "")[1]
@@ -687,9 +689,13 @@ def update_download_progress(book_id: str, progress: float) -> None:
     """Update download progress with throttled WebSocket broadcasts."""
     book_queue.update_progress(book_id, progress)
 
-    # Track activity for stall detection
+    # Only real progress changes should reset stall detection. Repeated keep-alive
+    # polls at the same percentage must not hide a stuck download forever.
     with _progress_lock:
-        _last_activity[book_id] = time.time()
+        last_progress = _last_progress_value.get(book_id)
+        if last_progress is None or progress != last_progress:
+            _last_activity[book_id] = time.time()
+        _last_progress_value[book_id] = progress
 
     # Broadcast progress via WebSocket with throttling
     if ws_manager:
@@ -728,13 +734,11 @@ def update_download_status(book_id: str, status: str, message: Optional[str] = N
     except ValueError:
         return
 
-    # Always update activity timestamp (used by stall detection) even if the status
-    # event is a duplicate keep-alive update.
     with _progress_lock:
-        _last_activity[book_id] = time.time()
         status_event = (status_key, message)
         if _last_status_event.get(book_id) == status_event:
             return
+        _last_activity[book_id] = time.time()
         _last_status_event[book_id] = status_event
 
     # Update status message first so terminal snapshots capture the final message
@@ -812,6 +816,7 @@ def _cleanup_progress_tracking(task_id: str) -> None:
         _progress_last_broadcast.pop(task_id, None)
         _progress_last_broadcast.pop(f"{task_id}_progress", None)
         _last_activity.pop(task_id, None)
+        _last_progress_value.pop(task_id, None)
         _last_status_event.pop(task_id, None)
 
 
@@ -892,70 +897,77 @@ def concurrent_download_loop() -> None:
         stalled_tasks: set[str] = set()  # Track tasks already cancelled due to stall
 
         while True:
-            # Clean up completed futures
-            completed_futures = [f for f in active_futures if f.done()]
-            for future in completed_futures:
-                task_id = active_futures.pop(future)
-                stalled_tasks.discard(task_id)
-                try:
-                    future.result()  # This will raise any exceptions from the worker
-                except Exception as e:
-                    logger.error_trace(f"Future exception for {task_id}: {e}")
-
-            # Check for stalled downloads (no activity in STALL_TIMEOUT seconds)
-            current_time = time.time()
-            with _progress_lock:
-                for future, task_id in list(active_futures.items()):
-                    if task_id in stalled_tasks:
-                        continue
-                    last_active = _last_activity.get(task_id, current_time)
-                    if current_time - last_active > STALL_TIMEOUT:
-                        logger.warning(f"Download stalled for {task_id}, cancelling")
-                        book_queue.cancel_download(task_id)
-                        book_queue.update_status_message(task_id, f"Download stalled (no activity for {STALL_TIMEOUT}s)")
-                        stalled_tasks.add(task_id)
-
-            # Start new downloads if we have capacity
-            while len(active_futures) < max_workers:
-                next_download = book_queue.get_next()
-                if not next_download:
-                    break
-
-                # Stagger concurrent downloads to avoid rate limiting on shared download servers
-                # Only delay if other downloads are already active
-                if active_futures:
-                    stagger_delay = random.uniform(2, 5)
-                    logger.debug(f"Staggering download start by {stagger_delay:.1f}s")
-                    time.sleep(stagger_delay)
-
-                task_id, cancel_flag = next_download
-
-                # Submit download job to thread pool
-                future = executor.submit(_process_single_download, task_id, cancel_flag)
-                active_futures[future] = task_id
-
-            # Brief sleep to prevent busy waiting
-            time.sleep(config.MAIN_LOOP_SLEEP_TIME)
+            try:
+                # Clean up completed futures
+                completed_futures = [f for f in active_futures if f.done()]
+                for future in completed_futures:
+                    task_id = active_futures.pop(future)
+                    stalled_tasks.discard(task_id)
+                    try:
+                        future.result()  # This will raise any exceptions from the worker
+                    except Exception as e:
+                        logger.error_trace(f"Future exception for {task_id}: {e}")
+
+                # Check for stalled downloads (no activity in STALL_TIMEOUT seconds)
+                current_time = time.time()
+                with _progress_lock:
+                    for future, task_id in list(active_futures.items()):
+                        if task_id in stalled_tasks:
+                            continue
+                        last_active = _last_activity.get(task_id, current_time)
+                        if current_time - last_active > STALL_TIMEOUT:
+                            logger.warning(f"Download stalled for {task_id}, cancelling")
+                            book_queue.cancel_download(task_id)
+                            book_queue.update_status_message(task_id, f"Download stalled (no activity for {STALL_TIMEOUT}s)")
+                            stalled_tasks.add(task_id)
+
+                # Start new downloads if we have capacity
+                while len(active_futures) < max_workers:
+                    next_download = book_queue.get_next()
+                    if not next_download:
+                        break
+
+                    # Stagger concurrent downloads to avoid rate limiting on shared download servers
+                    # Only delay if other downloads are already active
+                    if active_futures:
+                        stagger_delay = random.uniform(2, 5)
+                        logger.debug(f"Staggering download start by {stagger_delay:.1f}s")
+                        time.sleep(stagger_delay)
+
+                    task_id, cancel_flag = next_download
+
+                    # Submit download job to thread pool
+                    future = executor.submit(_process_single_download, task_id, cancel_flag)
+                    active_futures[future] = task_id
+
+                # Brief sleep to prevent busy waiting
+                time.sleep(config.MAIN_LOOP_SLEEP_TIME)
+            except Exception as e:
+                logger.error_trace("Download coordinator loop error: %s", e)
+                time.sleep(COORDINATOR_LOOP_ERROR_RETRY_DELAY)
 
 # Download coordinator thread (started explicitly via start())
 _coordinator_thread: Optional[threading.Thread] = None
-_started = False
+_coordinator_lock = Lock()
 
 
 def start() -> None:
     """Start the download coordinator thread. Safe to call multiple times."""
-    global _coordinator_thread, _started
+    global _coordinator_thread
 
-    if _started:
-        logger.debug("Download coordinator already started")
-        return
+    with _coordinator_lock:
+        if _coordinator_thread is not None and _coordinator_thread.is_alive():
+            logger.debug("Download coordinator already started")
+            return
 
-    _coordinator_thread = threading.Thread(
-        target=concurrent_download_loop,
-        daemon=True,
-        name="DownloadCoordinator"
-    )
-    _coordinator_thread.start()
-    _started = True
+        if _coordinator_thread is not None:
+            logger.warning("Download coordinator thread is not alive; starting a new one")
+
+        _coordinator_thread = threading.Thread(
+            target=concurrent_download_loop,
+            daemon=True,
+            name="DownloadCoordinator"
+        )
+        _coordinator_thread.start()
 
     logger.info(f"Download coordinator started with {config.MAX_CONCURRENT_DOWNLOADS} concurrent workers")

tests/download/test_orchestrator_lifecycle.py

@@ -0,0 +1,151 @@
+from __future__ import annotations
+
+from unittest.mock import ANY, MagicMock
+
+import pytest
+
+
+class _StopLoop(BaseException):
+    """Sentinel used to stop the infinite coordinator loop during tests."""
+
+
+class _FakeExecutor:
+    def __init__(self, *args, **kwargs) -> None:
+        self.args = args
+        self.kwargs = kwargs
+
+    def __enter__(self) -> _FakeExecutor:
+        return self
+
+    def __exit__(self, exc_type, exc, tb) -> bool:
+        return False
+
+    def submit(self, *args, **kwargs):  # pragma: no cover - not expected in these tests
+        raise AssertionError("submit() should not be called in this test")
+
+
+class _StopCoordinator(BaseException):
+    """Sentinel used to stop a real coordinator thread cleanly in tests."""
+
+
+def test_concurrent_download_loop_logs_and_recovers_after_loop_error(monkeypatch):
+    import shelfmark.download.orchestrator as orchestrator
+
+    call_count = 0
+
+    def fake_get_next():
+        nonlocal call_count
+        call_count += 1
+        if call_count == 1:
+            raise RuntimeError("boom")
+        return None
+
+    sleep_delays: list[float] = []
+
+    def fake_sleep(delay: float) -> None:
+        sleep_delays.append(delay)
+        if len(sleep_delays) >= 2:
+            raise _StopLoop()
+
+    mock_queue = MagicMock()
+    mock_queue.get_next.side_effect = fake_get_next
+
+    error_trace = MagicMock()
+
+    monkeypatch.setattr(orchestrator, "book_queue", mock_queue)
+    monkeypatch.setattr(orchestrator, "ThreadPoolExecutor", _FakeExecutor)
+    monkeypatch.setattr(orchestrator.time, "sleep", fake_sleep)
+    monkeypatch.setattr(orchestrator.logger, "error_trace", error_trace)
+
+    with pytest.raises(_StopLoop):
+        orchestrator.concurrent_download_loop()
+
+    assert mock_queue.get_next.call_count == 2
+    error_trace.assert_called_once_with("Download coordinator loop error: %s", ANY)
+    assert sleep_delays == [
+        orchestrator.COORDINATOR_LOOP_ERROR_RETRY_DELAY,
+        orchestrator.config.MAIN_LOOP_SLEEP_TIME,
+    ]
+
+
+def test_concurrent_download_loop_recovers_and_processes_task_after_transient_loop_error(monkeypatch):
+    import threading
+
+    import shelfmark.download.orchestrator as orchestrator
+
+    processed = threading.Event()
+
+    class FlakyQueue:
+        def __init__(self) -> None:
+            self.calls = 0
+
+        def get_next(self):
+            self.calls += 1
+            if self.calls == 1:
+                raise RuntimeError("boom")
+            if self.calls == 2:
+                return ("task-1", threading.Event())
+            if processed.is_set():
+                raise _StopCoordinator()
+            return None
+
+        def cancel_download(self, task_id: str) -> None:  # pragma: no cover - unused
+            raise AssertionError(f"cancel_download unexpectedly called for {task_id}")
+
+        def update_status_message(self, task_id: str, message: str) -> None:  # pragma: no cover - unused
+            raise AssertionError(f"update_status_message unexpectedly called for {task_id}: {message}")
+
+    queue = FlakyQueue()
+    error_trace = MagicMock()
+
+    monkeypatch.setattr(orchestrator, "book_queue", queue)
+    monkeypatch.setattr(
+        orchestrator,
+        "_process_single_download",
+        lambda task_id, cancel_flag: processed.set(),
+    )
+    monkeypatch.setattr(orchestrator.logger, "error_trace", error_trace)
+    monkeypatch.setattr(orchestrator, "COORDINATOR_LOOP_ERROR_RETRY_DELAY", 0.01)
+    monkeypatch.setattr(orchestrator.config, "MAX_CONCURRENT_DOWNLOADS", 1, raising=False)
+    monkeypatch.setattr(orchestrator.config, "MAIN_LOOP_SLEEP_TIME", 0.01, raising=False)
+
+    def run_loop() -> None:
+        try:
+            orchestrator.concurrent_download_loop()
+        except _StopCoordinator:
+            pass
+
+    thread = threading.Thread(target=run_loop, daemon=True, name="TestDownloadCoordinator")
+    thread.start()
+
+    assert processed.wait(timeout=1.0) is True
+    thread.join(timeout=1.0)
+
+    assert thread.is_alive() is False
+    assert queue.calls >= 3
+    error_trace.assert_called_once_with("Download coordinator loop error: %s", ANY)
+
+
+def test_start_replaces_dead_coordinator_thread(monkeypatch):
+    import shelfmark.download.orchestrator as orchestrator
+
+    dead_thread = MagicMock()
+    dead_thread.is_alive.return_value = False
+
+    new_thread = MagicMock()
+    new_thread.is_alive.return_value = True
+
+    thread_factory = MagicMock(return_value=new_thread)
+
+    monkeypatch.setattr(orchestrator, "_coordinator_thread", dead_thread)
+    monkeypatch.setattr(orchestrator.threading, "Thread", thread_factory)
+
+    orchestrator.start()
+
+    thread_factory.assert_called_once_with(
+        target=orchestrator.concurrent_download_loop,
+        daemon=True,
+        name="DownloadCoordinator",
+    )
+    new_thread.start.assert_called_once_with()
+    assert orchestrator._coordinator_thread is new_thread

tests/download/test_orchestrator_status.py

@@ -8,6 +8,7 @@ def test_update_download_status_dedupes_identical_events(monkeypatch):
 
     # Ensure clean module-level state
     orchestrator._last_activity.clear()
+    orchestrator._last_progress_value.clear()
     orchestrator._last_status_event.clear()
 
     mock_queue = MagicMock()
@@ -28,6 +29,52 @@ def test_update_download_status_dedupes_identical_events(monkeypatch):
     assert mock_queue.update_status_message.call_count == 1
     assert mock_ws.broadcast_status_update.call_count == 1
 
-    # Activity timestamp should still be updated on the duplicate keep-alive call.
-    assert orchestrator._last_activity[book_id] == 2.0
+    # Duplicate keep-alives should not refresh stall activity.
+    assert orchestrator._last_activity[book_id] == 1.0
 
+
+def test_update_download_progress_dedupes_identical_progress_for_activity(monkeypatch):
+    import shelfmark.download.orchestrator as orchestrator
+
+    book_id = "test-progress-book"
+
+    orchestrator._last_activity.clear()
+    orchestrator._last_progress_value.clear()
+    orchestrator._last_status_event.clear()
+
+    mock_queue = MagicMock()
+    monkeypatch.setattr(orchestrator, "book_queue", mock_queue)
+    monkeypatch.setattr(orchestrator, "ws_manager", None)
+
+    times = iter([10.0, 20.0])
+    monkeypatch.setattr(orchestrator.time, "time", lambda: next(times))
+
+    orchestrator.update_download_progress(book_id, 0.0)
+    orchestrator.update_download_progress(book_id, 0.0)
+
+    assert mock_queue.update_progress.call_count == 2
+    assert orchestrator._last_activity[book_id] == 10.0
+    assert orchestrator._last_progress_value[book_id] == 0.0
+
+
+def test_update_download_progress_refreshes_activity_when_progress_changes(monkeypatch):
+    import shelfmark.download.orchestrator as orchestrator
+
+    book_id = "test-progress-change"
+
+    orchestrator._last_activity.clear()
+    orchestrator._last_progress_value.clear()
+    orchestrator._last_status_event.clear()
+
+    mock_queue = MagicMock()
+    monkeypatch.setattr(orchestrator, "book_queue", mock_queue)
+    monkeypatch.setattr(orchestrator, "ws_manager", None)
+
+    times = iter([30.0, 40.0])
+    monkeypatch.setattr(orchestrator.time, "time", lambda: next(times))
+
+    orchestrator.update_download_progress(book_id, 0.0)
+    orchestrator.update_download_progress(book_id, 0.5)
+
+    assert orchestrator._last_activity[book_id] == 40.0
+    assert orchestrator._last_progress_value[book_id] == 0.5