fix: FormData stream exhausted on retry + undefined segments crash

Two bugs triggered together when the model was unloaded during a job:

1. submitJob() created FormData/createReadStream once outside the retry loop.
   After a 503, the audio ReadStream was consumed and subsequent retries sent
   an empty body to whisper, causing it to return segments:undefined.

2. webhook handler cast whisperJob.segments as Segment[] without guarding
   against undefined, so deduplicateSegments(undefined) crashed with
   'Cannot read properties of undefined (reading 'map')' — stored as job.error.

Fixes:
- Move FormData + createReadStream inside the retry loop (fresh stream per attempt)
- Use (whisperJob.segments ?? []) in webhook handler
- Add Array.isArray guard at top of deduplicateSegments() as belt-and-suspenders

Tests:
- New: verifies createReadStream called once per attempt (3 attempts = 3 streams)
- New: webhook handles segments:undefined without throwing
- New: webhook handles segments:null without throwing
- 150/150 passing

Co-authored-by: Copilot <223556219+Copilot@users.noreply.github.com>

src/lib/server/postprocess.ts

@@ -83,6 +83,7 @@ function ngramDedup(segments: Segment[]): Segment[] {
 // ── Full deduplication pipeline ──────────────────────────────────────────────
 
 export function deduplicateSegments(segments: Segment[]): Segment[] {
+	if (!Array.isArray(segments)) return [];
 	// 1. Collapse repeats within each segment's text
 	let result = segments.map((s) => ({
 		...s,

src/lib/server/whisper.ts

@@ -90,13 +90,16 @@ export async function submitJob(
 	const { createReadStream } = await import('fs');
 	const { default: fetch } = await import('node-fetch');
 
-	const form = new FormData();
-	form.append('audio', createReadStream(wavPath));
-	form.append('task', 'transcribe');
-	form.append('webhook_url', webhookUrl);
-	if (language) form.append('language', language);
-
 	for (let attempt = 1; attempt <= maxAttempts; attempt++) {
+		// Recreate form with a fresh readable stream on every attempt.
+		// A consumed ReadStream cannot be rewound, so reusing it across retries
+		// would send an empty body to whisper after the first 503.
+		const form = new FormData();
+		form.append('audio', createReadStream(wavPath));
+		form.append('task', 'transcribe');
+		form.append('webhook_url', webhookUrl);
+		if (language) form.append('language', language);
+
 		const res = await fetch(`${whisperUrl()}/jobs`, {
 			method: 'POST',
 			body: form,

src/routes/api/webhook/[jobId]/+server.ts

@@ -30,7 +30,7 @@ try {
 setJobStatus(jobId, 'processing', 90);
 emitProgress(jobId, { type: 'status', status: 'processing', progress: 90 });
 
-const rawSegments = whisperJob.segments as Segment[];
+const rawSegments = (whisperJob.segments ?? []) as Segment[];
 const segments = deduplicateSegments(rawSegments);
 
 const paths = await writeOutputs(segments, job.title, jobId);

src/tests/webhook.test.ts

@@ -289,6 +289,34 @@ describe('POST /api/webhook/[jobId] — empty segments', () => {
 	});
 });
 
+// ── Undefined / missing segments (model returned no segments field) ───────────
+
+describe('POST /api/webhook/[jobId] — undefined segments', () => {
+	it('completes the job as done when segments field is absent from whisper payload', async () => {
+		mockGetJob.mockReturnValue(makeJob('job-noseg'));
+		// Simulate whisper returning a result without a segments field
+		const payload = { ...makeWhisperJob(), segments: undefined as unknown as never[] };
+
+		const res = await POST(makeEvent('job-noseg', payload) as any);
+		expect(res.status).toBe(200);
+		expect(await res.json()).toEqual({ ok: true });
+		expect(mockUpdateJob).toHaveBeenCalledWith(
+			expect.objectContaining({ status: 'done', id: 'job-noseg' })
+		);
+	});
+
+	it('does not throw "cannot read properties of undefined" when segments is null', async () => {
+		mockGetJob.mockReturnValue(makeJob('job-nullseg'));
+		const payload = { ...makeWhisperJob(), segments: null as unknown as never[] };
+
+		// Must NOT throw — previously crashed with "Cannot read properties of undefined (reading 'map')"
+		await expect(POST(makeEvent('job-nullseg', payload) as any)).resolves.toBeDefined();
+		expect(mockUpdateJob).toHaveBeenCalledWith(
+			expect.objectContaining({ status: 'done' })
+		);
+	});
+});
+
 // ── Internal error handling ───────────────────────────────────────────────────
 
 describe('POST /api/webhook/[jobId] — internal errors', () => {

src/tests/whisper.test.ts

@@ -6,7 +6,8 @@ import { Readable } from 'stream';
 const mocks = vi.hoisted(() => ({
 	fetch: vi.fn(),
 	append: vi.fn(),
-	getHeaders: vi.fn(() => ({ 'content-type': 'multipart/form-data; boundary=test' }))
+	getHeaders: vi.fn(() => ({ 'content-type': 'multipart/form-data; boundary=test' })),
+	createReadStream: vi.fn(() => 'STREAM_PLACEHOLDER')
 }));
 
 vi.mock('node-fetch', () => ({ default: mocks.fetch }));
@@ -19,7 +20,7 @@ vi.mock('form-data', () => ({
 	})
 }));
 
-vi.mock('fs', () => ({ createReadStream: vi.fn(() => 'STREAM_PLACEHOLDER') }));
+vi.mock('fs', () => ({ createReadStream: mocks.createReadStream }));
 
 import { submitJob, streamJob, getModelStatus, cancelJob, unloadModel } from '$lib/server/whisper.js';
 
@@ -255,6 +256,20 @@ describe('submitJob — 503 retry behavior', () => {
 		expect(onModelWaiting).not.toHaveBeenCalled();
 	});
 
+	it('creates a fresh ReadStream for each attempt (stream not reused across retries)', async () => {
+		mocks.fetch.mockImplementation(
+			makeJobFetch(make503('loading', 0), make503('loading', 0), make202('fresh-stream-id'))
+		);
+
+		const id = await submitJob('/tmp/audio.wav', 'http://host/webhook', undefined, undefined, 10);
+		expect(id).toBe('fresh-stream-id');
+		// 3 attempts → 3 separate createReadStream calls, one fresh stream per form
+		expect(mocks.createReadStream).toHaveBeenCalledTimes(3);
+		expect(mocks.createReadStream).toHaveBeenNthCalledWith(1, '/tmp/audio.wav');
+		expect(mocks.createReadStream).toHaveBeenNthCalledWith(2, '/tmp/audio.wav');
+		expect(mocks.createReadStream).toHaveBeenNthCalledWith(3, '/tmp/audio.wav');
+	});
+
 	it('does NOT retry on non-503 errors (throws immediately)', async () => {
 		mocks.fetch.mockResolvedValue({
 			status: 400,