No AI client set a timeout: OpenAI's SDK waits 600s per attempt and retries
twice (timeouts included); google-genai waits forever. A hung provider call
had no upper bound, so recorrelation_sweep's 15-minute pipeline hold-back was
a guess against an unbounded tail.
- config: stt_timeout_seconds (120), openai_timeout_seconds (60),
openai_max_retries (1), gemini_timeout_seconds (60).
- app/internal/ai_clients.py builds every OpenAI/AsyncOpenAI client with them
(transcription, extraction, embeddings, summarizer, vocabulary learner,
trip chat). gemini.py's shared client gets HttpOptions(timeout=ms).
- A timeout raises like any other provider error, so existing fallbacks are
unchanged: rules-only correlation, rules decision on tiebreak, raw
transcript on correction, ai_health "transient".
- MIN_MINUTES_SINCE_PIPELINE_START is now derived from those timeouts
(pipeline_worst_case_seconds, 3-scene budget + 2 min non-AI slack), floor
15: 21 min with the defaults. Loop warns if it reaches the scan window.
- tests/test_ai_timeouts.py: client limits, a real hung-socket request that
gives up in <5s, timeout fallback per tier, the derived bound, and a guard
against any new OpenAI( outside ai_clients.py.
Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
