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[AZ-687] [autodev] File replay-mode guard task + Tier-2 evidence
Jetson Tier-2 e2e on 2026-05-19 11:27 surfaced a NEW gap one phase deeper than where Rerun 3 died: build_pre_constructed seeds c6_descriptor_index unconditionally, which reads config.components["c6_tile_cache"] via storage_factory._c6_config. The replay CLI synthesizes a Config that has no c6_tile_cache block, so AC-1/2/5/6 fail with KeyError 'c6_tile_cache'. Bootstrap (no source code changes): - AZ-687 (Story, To Do, 2pt, Epic AZ-602; blocks AZ-618) - Task spec in _docs/02_tasks/todo/ - _dependencies_table.md row + header narrative - _docs/_autodev_state.md detail repointed at AZ-687 - _docs/03_implementation/jetson_runs/ Tier-2 evidence The fix itself lives in batch 97 (next session): guard the c6/c7 seeds at the BUILD-PRE-CONSTRUCTED layer when config.mode == "replay". Per existing storage_factory._c6_config docstring the silent-fallback path is explicitly rejected — the bootstrap layer is the right seam. Co-authored-by: Cursor <cursoragent@cursor.com>
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Oleksandr Bezdieniezhnykh
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# AZ-687 — build_pre_constructed must guard c6_descriptor_index when config.mode == 'replay'
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**Task**: AZ-687_pre_constructed_replay_mode_guard
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**Name**: build_pre_constructed must guard c6_descriptor_index when config.mode == 'replay'
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**Description**: Follow-up to AZ-618 (umbrella) surfaced by the 2026-05-19 Jetson Tier-2 e2e run. The newly-wired `build_pre_constructed` unconditionally seeds `c6_descriptor_index`, which reads `config.components["c6_tile_cache"]` via `storage_factory._c6_config`. In replay mode the CLI synthesizes a `Config` that does NOT include a `c6_tile_cache` block, so the call raises `KeyError`. The descriptor index is not consumed in replay mode (replay sources frames from the tlog + mp4 directly), so the fix is a replay-mode guard at the bootstrap layer — NOT a silent fallback in `_c6_config` (the docstring explicitly rejects that to keep import-time wiring honest).
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**Complexity**: 2 points
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**Dependencies**: AZ-619, AZ-620, AZ-624 (the c6 seed introduced by AZ-620 and wired by AZ-624 must already be in `done/` — they are, as of batch 96).
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**Component**: runtime_root (cross-cutting)
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**Tracker**: AZ-687
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**Epic**: AZ-602 (parent: AZ-618 umbrella; AZ-687 is a sibling follow-up under the same Epic)
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## Outcome
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- `runtime_root/airborne_bootstrap.py::build_pre_constructed` (or its `_build_c6_descriptor_index` helper) guards the c6 descriptor index + c6 tile store seeds on `config.mode == "replay"`.
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- Equivalent guard applied to any other c6/c7/cN seed whose underlying `_cN_config` lookup fails on a replay-synthesized config AND whose result is not consumed by the replay path.
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- New unit test pins the replay-mode path; existing live-mode tests continue to assert every key in `AIRBORNE_REQUIRED_PRE_CONSTRUCTED_KEYS` is populated.
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- Jetson Tier-2 e2e replay run crosses both `replay.compose_root.ready` AND `replay.input.frame_emitted` log lines on AC-1, AC-2, AC-5, AC-6.
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## Scope
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### Included
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- Replay-mode guard inside `runtime_root/airborne_bootstrap.py` covering the c6 descriptor index + c6 tile store seeds (and any other replay-irrelevant seed that currently relies on a config block the replay CLI does not synthesize).
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- New unit test under `tests/unit/runtime_root/` (e.g. `test_az687_pre_constructed_replay_mode.py`) that builds a replay-mode Config with no `c6_tile_cache` block and asserts `build_pre_constructed(config)` returns successfully.
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- Live-mode regression coverage: extend or assert against existing tests so they continue to require every documented key.
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- Re-run Jetson Tier-2 via `scripts/run-tests-jetson.sh` (compose-bypass path documented in `_docs/03_implementation/run_tests_step11_report.md` Rerun 3 if companion/operator-orchestrator builds remain broken on the Jetson).
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- Batch report `Tier-2 evidence:` field populated per `_docs/02_document/tests/tier2-jetson-testing.md`.
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### Excluded
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- Any change to component factory signatures or per-component config schemas.
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- New `BUILD_*` env flags.
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- Operator-binary `pre_constructed` assembly (still explicitly deferred per AZ-591).
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- Fixing the operator-orchestrator Dockerfile build order (`pip install -e .` before `COPY src ./src`) — unrelated; this task uses the compose-bypass workaround.
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- AC-3 (camera calibration xfail) or AC-8 (mock-sat dep) — both have their own existing gates.
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## Acceptance Criteria
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**AC-687-1: replay-mode build_pre_constructed succeeds without c6_tile_cache block**
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Given a `Config` with `mode == "replay"` and `components` that do NOT include a `c6_tile_cache` block
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When `build_pre_constructed(config)` is called
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Then it returns without raising `KeyError`
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And the returned dict either omits `c6_descriptor_index` / `c6_tile_store` or maps them to a sentinel the consuming wrapper factories recognise as "not built for replay".
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**AC-687-2: live-mode build_pre_constructed continues to seed every required key**
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Given a `Config` with `mode == "live"` and the full default `components` block
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When `build_pre_constructed(config)` is called
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Then the returned dict contains every key in `set.union(*AIRBORNE_REQUIRED_PRE_CONSTRUCTED_KEYS.values())`
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And no key maps to `None`.
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**AC-687-3: Jetson Tier-2 e2e crosses both bootstrap log lines**
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Given AZ-687 is landed
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When `scripts/run-tests-jetson.sh tests/e2e/replay/test_derkachi_1min.py` is invoked (or its compose-bypass equivalent)
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Then AC-1, AC-2, AC-5, AC-6 each log `replay.compose_root.ready` AND `replay.input.frame_emitted`
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And the batch report `Tier-2 evidence:` field captures terminal log path, JetPack version (6.2.2+b24), L4T (R36.5.0), and run timestamp.
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**AC-687-4: full Tier-1 pytest suite green**
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Given AZ-687 is landed
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When the full Tier-1 pytest suite is run
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Then 0 new failures appear (the existing pre-existing `c12_operator_orchestrator/test_cli_console_script.py::test_cold_start_under_500ms_p99` Mac-dev-host failure remains out of scope).
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## Constraints
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- MUST NOT change `_c6_config` to fall back silently — silent fallback was explicitly rejected per the existing docstring (the rationale: "if the package has not been imported, KeyError here is the right failure mode — silent fallback would mask a missing import"). The fix lives at the BUILD-PRE-CONSTRUCTED layer, not the storage_factory layer.
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- MUST NOT introduce new `BUILD_*` env flags.
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- MUST NOT touch per-component factory signatures.
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## Evidence
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- Jetson run log (failure evidence): `_docs/03_implementation/jetson_runs/2026-05-19_az618_tier2_run.txt`
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- AZ-618 umbrella spec (defines AC-5 expectations): `_docs/02_tasks/done/AZ-618_airborne_bootstrap_pre_constructed.md`
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- AZ-620 Phase B (introduces `_build_c6_descriptor_index`): `_docs/02_tasks/done/AZ-620_pre_constructed_phase_b_c6_storage.md`
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- AZ-624 Phase F (wires `main()`): `_docs/02_tasks/done/AZ-624_pre_constructed_phase_f_wire_main.md`
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- `_c6_config` rationale: `src/gps_denied_onboard/runtime_root/storage_factory.py:55-62`
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- Tier-2 testing policy: `_docs/02_document/tests/tier2-jetson-testing.md`
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## Tracker relationships
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- Parent Epic: AZ-602 (E2E Tier-1 harness rehabilitation)
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- Surfaces from: AZ-618 (umbrella) — specifically AC-618-5 Jetson Tier-2 reality gate
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