pi-smart-router 0.16.2 → 0.18.0

package/.pi/extensions/smart-router/route-and-delegate.ts

@@ -16,6 +16,7 @@ import {
 import {
   assertRoutableFleetAfterGeminiToolHistoryGuard,
   GEMINI_TOOL_HISTORY_EXCLUDED,
+  isGoogleGeminiProfile,
   resolveEffectiveFleet,
 } from '../../../src/domain/routing/tool-history-guard.js';
 import type { ModelProfile, RoutingDecision, RoutingRequest } from '../../../src/domain/types/index.js';
@@ -24,6 +25,7 @@ import {
   isGeminiThoughtSignatureAssistantError,
   parseAssistantMessageError,
 } from '../../../src/infrastructure/delegation/provider-error.js';
+import { GEMINI_REPLAY_INCOMPATIBLE } from '../../../src/infra/gemini-provider.js';
 import { shouldFailoverOnProviderError } from '../../../src/infrastructure/gateway/gateway-dispatch.js';
 import {
   commitPipedTerminal,
@@ -52,6 +54,11 @@ function isPipedResult(
   return 'heldTerminal' in result;
 }
 
+/** Fail-open reason codes (SP-226) — emitted in telemetry and SMART_ROUTER_LOG_ROUTING=1. */
+export const NO_REGISTRY_MODEL = 'no_registry_model';
+export const FAILOVER_EXHAUSTED = 'failover_exhausted';
+export const DELEGATION_ABORTED = 'delegation_aborted';
+
 function isRoutingLogEnabled(): boolean {
   return process.env.SMART_ROUTER_LOG_ROUTING === '1';
 }
@@ -152,6 +159,68 @@ function isZeroOutputLengthStop(message: AssistantMessage): boolean {
   return message.stopReason === 'length' && message.usage.output === 0;
 }
 
+/** Minimal model identity for degraded terminal messages when no Model resolved. */
+interface DegradedModelRef {
+  readonly api: Api;
+  readonly provider: string;
+  readonly id: string;
+}
+
+function createDegradedErrorMessage(
+  model: DegradedModelRef,
+  reasonCode: string,
+  detail: string,
+): AssistantMessage {
+  return {
+    role: 'assistant',
+    content: [],
+    api: model.api,
+    provider: model.provider,
+    model: model.id,
+    usage: {
+      input: 0,
+      output: 0,
+      cacheRead: 0,
+      cacheWrite: 0,
+      totalTokens: 0,
+      cost: { input: 0, output: 0, cacheRead: 0, cacheWrite: 0, total: 0 },
+    },
+    stopReason: 'error',
+    errorMessage: `Smart router degraded response (${reasonCode}): ${detail}`,
+    timestamp: Date.now(),
+  };
+}
+
+/**
+ * Fail-open terminal (SP-226): never throw to the host on exhaustion paths.
+ * Emit a structured warning with the reason code and end the outer stream with
+ * a degraded error message so the pi host receives an actionable response.
+ */
+function emitDegradedFailure(
+  outer: AssistantMessageEventStream,
+  model: DegradedModelRef | undefined,
+  selectedModelId: string,
+  reasonCode: string,
+  detail: string,
+): void {
+  console.warn(
+    '[smart-router] fail-open degraded response',
+    JSON.stringify({
+      reason_code: reasonCode,
+      selected_model_id: selectedModelId,
+      detail,
+    }),
+  );
+  const ref: DegradedModelRef = model ?? {
+    api: 'unknown',
+    provider: 'unknown',
+    id: selectedModelId,
+  };
+  const errorMessage = createDegradedErrorMessage(ref, reasonCode, detail);
+  outer.push({ type: 'error', reason: 'error', error: errorMessage });
+  outer.end(errorMessage);
+}
+
 function buildOverflowRoutingDecision(
   base: RoutingDecision,
   fallback: ReturnType<typeof resolveContextOverflowFallback>,
@@ -357,9 +426,18 @@ export async function routeAndDelegate(
     if (decision.selected_model_id === 'unknown' && guardResult) {
       assertRoutableFleetAfterGeminiToolHistoryGuard(guardResult);
     }
-    throw new Error(
+    // SP-226 fail-open: no registry model resolved — degrade instead of throwing.
+    deps.router.dispatch.recordOutcome(decision.selected_model_id, {
+      code: 'NO_REGISTRY_MODEL',
+    });
+    emitDegradedFailure(
+      outer,
+      undefined,
+      decision.selected_model_id,
+      NO_REGISTRY_MODEL,
       `No registry model available for routing decision ${decision.selected_model_id}`,
     );
+    return;
   }
 
   logRoutingDecision(decision, {
@@ -370,6 +448,7 @@ export async function routeAndDelegate(
 
   const failedModelIds: string[] = [];
   const headroomExcludedModelIds: string[] = [];
+  let geminiReplayFailoverAttempted = false;
   const estimatedInputTokens =
     request.estimated_input_tokens ?? request.prompt_text.length;
   let pendingFailoverInfo: FailoverNoticeInfo | undefined;
@@ -494,6 +573,60 @@ export async function routeAndDelegate(
         result.finalMessage &&
         isGeminiThoughtSignatureAssistantError(result.finalMessage)
       ) {
+        // SP-233 residual safety net: a thought_signature 400 that survived
+        // repair/guard means the session replay state is incompatible with
+        // Gemini — fail over ONCE to a non-Google fleet member so the agent
+        // loop continues. Never counted as provider infra failure; never
+        // Gemini↔Gemini.
+        if (!geminiReplayFailoverAttempted) {
+          geminiReplayFailoverAttempted = true;
+          if (!failedModelIds.includes(targetModel.id)) {
+            failedModelIds.push(targetModel.id);
+          }
+          const nonGoogleFleet = effectiveFleet.filter(
+            (profile) => !isGoogleGeminiProfile(profile),
+          );
+          const replayFailover =
+            nonGoogleFleet.length > 0
+              ? deps.router.dispatch.selectFailover(
+                  decision,
+                  failedModelIds,
+                  nonGoogleFleet,
+                )
+              : undefined;
+          const failover = replayFailover
+            ? { ...replayFailover, reason_code: GEMINI_REPLAY_INCOMPATIBLE }
+            : undefined;
+          const alternateModel = failover ? resolveTargetModel(deps, failover) : undefined;
+
+          if (failover && alternateModel && alternateModel.id !== targetModel.id) {
+            console.warn(
+              '[smart-router] gemini replay incompatible, failing over to non-Google model',
+              alternateModel.id,
+            );
+            if (isRoutingLogEnabled()) {
+              console.warn(
+                '[smart-router] routing decision',
+                JSON.stringify({
+                  reason_code: GEMINI_REPLAY_INCOMPATIBLE,
+                  failed_model_id: targetModel.id,
+                  selected_model_id: alternateModel.id,
+                }),
+              );
+            }
+            pendingFailoverInfo = {
+              failedModelId: targetModel.id,
+              alternateModelId: alternateModel.id,
+              errorObj: resolveFailoverProviderError(result.finalMessage),
+            };
+            decision = failover;
+            deps.onRoutingDecision?.(decision);
+            targetModel = alternateModel;
+            continue;
+          }
+        }
+        // No non-Google candidate (or one-shot already used): actionable
+        // terminal guidance — never a silent loop.
         commitPipedTerminal(result, { sanitizeErrors: true });
         return;
       }
@@ -546,6 +679,16 @@ export async function routeAndDelegate(
       return;
     } catch (error) {
       if (isAbortError(error, options)) {
+        // SP-226: telemetry for phase-boundary aborts (previously silent).
+        if (isRoutingLogEnabled()) {
+          console.warn(
+            '[smart-router] delegation aborted',
+            JSON.stringify({
+              reason_code: DELEGATION_ABORTED,
+              model_id: targetModel.id,
+            }),
+          );
+        }
         const abortMessage = createErrorMessage(targetModel, options, error);
         outer.push({ type: 'error', reason: 'aborted', error: abortMessage });
         outer.end(abortMessage);
@@ -565,7 +708,7 @@ export async function routeAndDelegate(
       );
       const alternateModel = failover ? resolveTargetModel(deps, failover) : undefined;
 
-      if (alternateModel && alternateModel.id !== targetModel.id) {
+      if (failover && alternateModel && alternateModel.id !== targetModel.id) {
         console.warn(
           '[smart-router] stream delegation failed, failing over',
           error instanceof Error ? error.message : String(error),
@@ -575,9 +718,6 @@ export async function routeAndDelegate(
           alternateModelId: alternateModel.id,
           errorObj: { message: error instanceof Error ? error.message : String(error) },
         };
-        if (!failover) {
-          throw error;
-        }
         decision = failover;
         targetModel = alternateModel;
         continue;
@@ -585,7 +725,16 @@ export async function routeAndDelegate(
 
       const fallbackModel = resolveFallbackModel(deps, effectiveFleet);
       if (!fallbackModel || fallbackModel.id === targetModel.id) {
-        throw error;
+        // SP-226 fail-open: fleet/failover exhausted and no distinct safe
+        // default — degrade instead of throwing to the host.
+        emitDegradedFailure(
+          outer,
+          targetModel,
+          decision.selected_model_id,
+          FAILOVER_EXHAUSTED,
+          error instanceof Error ? error.message : String(error),
+        );
+        return;
       }
 
       console.warn(

package/.pi/extensions/smart-router/routing-context.ts

@@ -76,6 +76,35 @@ function messageContentToString(content: string | readonly (TextContent | { type
     .join('\n');
 }
 
+/**
+ * SP-225 / #137: read an HTTP-ish status a host may attach to a tool result
+ * (either directly on the message or inside `details`). Returns undefined
+ * when no finite numeric status is present.
+ */
+function readOptionalStatus(source: unknown): number | undefined {
+  if (source === null || typeof source !== 'object') {
+    return undefined;
+  }
+  const record = source as Record<string, unknown>;
+  const direct = record.status;
+  if (typeof direct === 'number' && Number.isFinite(direct) && direct >= 0) {
+    return Math.floor(direct);
+  }
+  return readOptionalStatus(record.details);
+}
+
+export interface MapContextMessagesOptions {
+  /**
+   * Opt-in: include assistant `thinking` blocks in routing `content`.
+   * Default false — thinking is model-internal reasoning, not a routing
+   * signal, and leaking it inflates token estimates (#137).
+   */
+  includeThinking?: boolean;
+}
+
+/** Operator env gate restoring the pre-SP-225 thinking-in-content behavior. */
+const INCLUDE_THINKING_ENV = 'SMART_ROUTER_INCLUDE_THINKING';
+
 export function extractPromptText(messages: readonly Message[]): string {
   for (let i = messages.length - 1; i >= 0; i--) {
     const message = messages[i];
@@ -117,7 +146,11 @@ export function deriveTurnType(messages: readonly Message[]): TurnType {
   return 'main_loop';
 }
 
-export function mapContextMessages(messages: readonly Message[]): RoutingMessage[] {
+export function mapContextMessages(
+  messages: readonly Message[],
+  options?: MapContextMessagesOptions,
+): RoutingMessage[] {
+  const includeThinking = options?.includeThinking === true;
   return messages.map((message) => {
     if (message.role === 'user') {
       return {
@@ -127,27 +160,53 @@ export function mapContextMessages(messages: readonly Message[]): RoutingMessage
     }
 
     if (message.role === 'assistant') {
-      const content = message.content
-        .map((block) => {
-          if (block.type === 'text') {
-            return block.text;
+      const contentParts: string[] = [];
+      const toolBlocks: Record<string, unknown>[] = [];
+      for (const block of message.content) {
+        if (block.type === 'text') {
+          contentParts.push(block.text);
+        } else if (block.type === 'thinking') {
+          if (includeThinking) {
+            contentParts.push(block.thinking);
           }
-          if (block.type === 'thinking') {
-            return block.thinking;
-          }
-          return '';
-        })
-        .filter(Boolean)
-        .join('\n');
+        } else if (block.type === 'toolCall') {
+          toolBlocks.push({
+            type: 'tool_call',
+            tool_call_id: block.id,
+            tool_name: block.name,
+          });
+        }
+      }
 
-      return { role: message.role, content };
+      const mapped: RoutingMessage = {
+        role: message.role,
+        content: contentParts.filter(Boolean).join('\n'),
+      };
+      if (toolBlocks.length > 0) {
+        return { ...mapped, tool_blocks: toolBlocks };
+      }
+      return mapped;
     }
 
+    const status = readOptionalStatus(message);
+    // When a host attaches an HTTP-ish status, let the domain status>=400 rule
+    // arbitrate (#137): a bare isError=false would otherwise mask the
+    // structured signal. Without a status, preserve the host isError verbatim.
+    const isError = message.isError === true || status === undefined
+      ? message.isError
+      : undefined;
     return {
       role: 'tool',
       content: messageContentToString(message.content),
-      tool_blocks: [],
-      is_error: message.isError,
+      tool_blocks: [
+        {
+          type: 'tool_result',
+          tool_call_id: message.toolCallId,
+          tool_name: message.toolName,
+        },
+      ],
+      ...(isError !== undefined ? { is_error: isError } : {}),
+      ...(status !== undefined ? { status } : {}),
     };
   });
 }
@@ -164,7 +223,9 @@ export function buildRoutingRequest(
     request_id: randomUUID(),
     session_id: sessionId,
     prompt_text: extractPromptText(context.messages),
-    messages: mapContextMessages(context.messages),
+    messages: mapContextMessages(context.messages, {
+      includeThinking: process.env[INCLUDE_THINKING_ENV] === '1',
+    }),
     turn_type: deriveTurnType(context.messages),
     estimated_input_tokens: estimateInputTokens(context, options),
     ...lifecycleFlags,

package/README.md

@@ -2,7 +2,7 @@
 
 **Auto-model router middleware for the [pi](https://pi.dev) coding agent.**
 
-> **v0.1.0** is initial development (SemVer `0.y.z`). The public API and routing behavior may change until `1.0.0`.
+> Current release: **v0.16.2** (mirrors `package.json`; SemVer `0.y.z`). The public API and routing behavior may change until `1.0.0`.
 
 pi-smart-router intercepts every LLM inference request and dynamically routes it to the optimal execution engine — balancing cost, capability, latency, and time-to-first-token (TTFT) — without requiring you to manually pick a model for each turn.
 
@@ -18,8 +18,8 @@ pi-smart-router intercepts every LLM inference request and dynamically routes it
 ```text
 request → hardware probe → loop escalation → turn envelope → context-fit gate
         → low-intensity tier gate → session pin → deterministic triage
-        → local zero-tier → HyDRA embedding matcher → safe cloud default
-        → context overflow fallback
+        → local zero-tier → triage cloud fallback → HyDRA embedding matcher
+        → safe cloud default → context overflow fallback
 ```
 
 The pipeline runs **12 stages sequentially with early exit** — the moment any stage reaches a routing decision, subsequent stages are skipped. Every decision includes the stage name, reason code, candidates considered, estimated cost, and routing latency for full observability.
@@ -34,6 +34,7 @@ The pipeline runs **12 stages sequentially with early exit** — the moment any
 | Session Pin | <1ms | Returns pinned model if session has one; breaks pin on compaction or overflow |
 | Deterministic Triage | <5ms | Aho-Corasick keyword scan + cyclomatic complexity analysis |
 | Local Zero-Tier | <15ms | Pings LM Studio + Ollama in parallel; routes locally when eligible |
+| Triage Cloud Fallback | <2ms | Trivial prompts not claimed locally route to the first healthy economical-cloud model |
 | HyDRA Matcher | 80-120ms | ONNX embeddings, 3D requirement projection, shortfall gate, multi-objective scoring |
 | Safe Cloud Default | — | First healthy economical-cloud model (context-fit aware) |
 | Context Overflow Fallback | — | Escalates to largest-fit model when economical tiers cannot fit |
@@ -200,7 +201,7 @@ pi exposes two different **auto** models. They are easy to confuse but play diff
 
 - You want cost/capability-aware model selection across your full authenticated fleet
 - You rely on session pinning, failover, or `/smart-router status` / `history` / `stats` telemetry
-- Tool-heavy sessions with Gemini economical models work via in-repo replay repair; add `cursor/auto` for unrepairable Google replay edge cases (see [pi-smart-router#85](https://github.com/beettlle/pi-smart-router/issues/85))
+- Tool-heavy sessions with Gemini economical models work via in-repo replay repair (cross-provider included); the tool-history guard reroutes to non-Google models such as `cursor/auto` for unrepairable replay state (see [pi-smart-router#85](https://github.com/beettlle/pi-smart-router/issues/85), [pi-smart-router#158](https://github.com/beettlle/pi-smart-router/issues/158))
 
 Cursor models (`cursor/*`, `composer-*`, and the opaque fleet id `default`) map to **frontier-cloud** tier in `pi-model-mapper.ts` so HyDRA can score them against Gemini and Claude instead of treating them as unknown economical models ([pi-smart-router#40](https://github.com/beettlle/pi-smart-router/issues/40), [pi-smart-router#70](https://github.com/beettlle/pi-smart-router/issues/70)). Related: [pi-smart-router#23](https://github.com/beettlle/pi-smart-router/issues/23) (turn envelope / pin order), [pi-smart-router#37](https://github.com/beettlle/pi-smart-router/issues/37) (Gemini `thought_signature` errors).
 
@@ -258,6 +259,10 @@ After typing `/smart-router ` (with a trailing space), press **TAB** to see subc
 npm run verify:ci
 ```
 
+## Concurrency contract
+
+`RouterPipeline.route()` calls on a single router instance are **single-flight**: concurrent calls are serialized internally (SP-230, [#141](https://github.com/beettlle/pi-smart-router/issues/141)). The pipeline keeps per-route transient state on instance fields while stages run, so overlapping executions are queued rather than interleaved — each queued call waits at most one routing latency. This applies to `createRouter()` / `createRouterFromFleet()` handles: a shared `router.dispatch` is safe to call concurrently, and serialization does not change routing policy outcomes. For parallel routing throughput, create separate router instances.
+
 ## Fleet behavior
 
 When you use `smart-router/auto`, the extension does **not** read `config/models.yaml`. Instead:
@@ -873,23 +878,25 @@ The `GatewayDispatch` layer wraps the pipeline with:
 
 #### Gemini `thought_signature` 400 errors
 
-If Gemini returns **400 INVALID_ARGUMENT** mentioning `thought_signature`, the router treats this as a **protocol validation error** (incomplete tool-call replay), not provider unavailability — it will **not** failover to another model.
+If Gemini returns **400 INVALID_ARGUMENT** mentioning `thought_signature`, the router treats this as a **protocol validation error** (incomplete tool-call replay), not provider unavailability — it is never classified as an infrastructure failure and never trips the circuit breaker. If the error survives repair and the tool-history guard, the router fails over **once** to a non-Google fleet model automatically (telemetry `reason_code: gemini_replay_incompatible`, distinct from infra failover) so the agent loop continues; only when no non-Google candidate exists does it surface a terminal error with actionable guidance.
 
 See [Google's thought signatures documentation](https://ai.google.dev/gemini-api/docs/generate-content/thought-signatures).
 
-**Primary fix — replay repair (SP-127/128):** before every Google-target delegation, smart-router repairs tool-call replay state: prior turns keep captured `thoughtSignature` values; tool calls missing a signature receive the Google-accepted skip sentinel so pi-ai can replay without a 400. Typical Gemini-first tool loops on `/model smart-router/auto` no longer require `/new` or switching away from Google models.
+**Primary path — silent repair and reroute (SP-127/128, SP-231/232):** in the common cross-provider case (tool-heavy turns on OpenAI/Anthropic/GLM/Cursor, then a Gemini selection) you do **not** need `/new` or manual model switching. Before every Google-target delegation, smart-router repairs tool-call replay state for **any** prior provider: unsigned tool calls receive the Google-accepted skip sentinel, captured signatures are preserved, and assistant identity aligns so pi-ai replays the turns without a 400. When history carries replay state repair cannot make Google-safe, the tool-history guard silently reroutes to a non-Google model instead (`reason_code: gemini_tool_history_excluded`) — see below.
 
-**Narrowed guard fail-safe (SP-129):** sessions with **unrepairable** Google-origin replay state (e.g. redacted thinking blocks paired with tool calls) exclude Gemini from routing (`reason_code: gemini_tool_history_excluded`) unless the operator sets `force_model_id` via `/model`. Repairable Google tool history is delegated normally.
+**Guard fail-safe (SP-129, expanded SP-232):** sessions with **unrepairable** replay state exclude Gemini from routing unless the operator sets `force_model_id` via `/model`. Unrepairable means: Google-origin turns with redacted thinking or captured signatures (SP-129), and — after SP-232 — **cross-provider** turns whose state repair preserves but Google rejects, such as foreign provider signatures (Claude signed thinking, signed text, or signed tool calls) or redacted thinking from any origin replayed toward a Google target. Unsigned cross-provider tool calls alone are repairable and stay routable to Gemini.
 
-**Empty fleet fail-safe (SP-084):** when the guard filters every model in the scoped fleet (e.g. Google/Gemini-only dogfood configs with unrepairable replay risk), the router throws an actionable error instead of delegating with `selected_model_id: unknown`. Add a non-Google model such as `openai/gpt-4o-mini` or `cursor/auto` to the fleet, start `/new`, or pin `/model` to force a specific model.
+**Empty fleet fail-safe (SP-084):** when the guard filters every model in the scoped fleet (e.g. Google/Gemini-only dogfood configs with unrepairable replay risk), the router throws an actionable error instead of delegating with `selected_model_id: unknown`. Add a non-Google model such as `openai/gpt-4o-mini` or `cursor/auto` to the fleet, or pin `/model` to force a specific model.
+
+**Residual path — one-shot non-Google failover (SP-233):** when a `thought_signature` 400 still reaches the stream (repair could not make the session replay state Google-safe), smart-router selects at most one non-Google fleet member and continues the stream with it. This is protocol-affinity failover, not infra failover: it is not recorded as a provider outage, does not trip the circuit breaker, and never retries Gemini↔Gemini for this error. If the scoped fleet has no non-Google model, the router fails fast with terminal guidance instead of looping silently.
 
 **If you still see a `thought_signature` error:**
 
-1. Start a fresh session with `/new` in pi (clears unrepairable history).
-2. Switch to a non-Google model (e.g. `/model openai/gpt-4o-mini`) for that session.
+1. Add a non-Google model (e.g. `openai/gpt-4o-mini` or `cursor/auto`) to the scoped fleet so the residual failover can reroute automatically — or switch manually with `/model openai/gpt-4o-mini` for that session.
+2. Start a fresh session with `/new` in pi (clears unrepairable history) — last resort, rarely needed outside Google-only fleets or residual edge cases.
 3. Upstream: [pi#6342](https://github.com/earendil-works/pi/issues/6342) tracks pi preserving thought signatures in session replay; smart-router repair covers the common cross-model routing case without waiting on that fix.
 
-Related: [pi-smart-router#37](https://github.com/beettlle/pi-smart-router/issues/37), [pi-smart-router#38](https://github.com/beettlle/pi-smart-router/issues/38), [pi-smart-router#40](https://github.com/beettlle/pi-smart-router/issues/40), [pi-smart-router#41](https://github.com/beettlle/pi-smart-router/issues/41), [pi-smart-router#85](https://github.com/beettlle/pi-smart-router/issues/85).
+Related: [pi-smart-router#37](https://github.com/beettlle/pi-smart-router/issues/37), [pi-smart-router#38](https://github.com/beettlle/pi-smart-router/issues/38), [pi-smart-router#40](https://github.com/beettlle/pi-smart-router/issues/40), [pi-smart-router#41](https://github.com/beettlle/pi-smart-router/issues/41), [pi-smart-router#85](https://github.com/beettlle/pi-smart-router/issues/85), [pi-smart-router#158](https://github.com/beettlle/pi-smart-router/issues/158), [pi-smart-router#159](https://github.com/beettlle/pi-smart-router/issues/159).
 
 ### Explain endpoint (library API)
 
@@ -949,7 +956,7 @@ Contributors must run `npm run build` before publishing or consuming the library
 | `npm run release:check` | Pre-release gate: `verify:ci` + consumer pack + Tier 0 functional smoke |
 | `npm run release:functional-smoke` | Tier 0 functional smoke: calibration verify (`--skip-embed`), benchmark profiles, release gate assertions |
 | `npm run release:consumer-pack` | Pack tarball and verify production dependencies resolve (catches missing runtime deps) |
-| `npm run verify:ci` | Full CI parity: build, typecheck, lint, test, coverage |
+| `npm run verify:ci` | Full CI parity: build, typecheck, lint, test, coverage (baseline PR gate; see [PR and pre-release quality gate set](#pr-and-pre-release-quality-gate-set)) |
 | `npm run typecheck` | TypeScript strict mode check (`tsc --noEmit`) |
 | `npm test` | Run test suite (`vitest run`) |
 | `npm run coverage:check` | Tests with line-coverage thresholds |
@@ -1008,7 +1015,9 @@ npm run routing:eval-replay
 npm run routing:twinrouterbench:full-track
 ```
 
-**CI smoke:** `.github/workflows/eval-harness-smoke.yml` runs on PRs that touch eval scripts, fixtures, or the workflow. It executes `routing:eval-harness:smoke`, `routing:eval-harness:corpus-smoke`, and eval unit tests — fast, offline, no provider network calls. Job timeout stays at 10 minutes. The optional full-track nightly (`.github/workflows/twinrouterbench-full-nightly.yml`, `schedule` + `workflow_dispatch` only) is **not** on `pull_request` and must not be configured as a required status check — failures there do not gate PR CI or `release:functional-smoke`.
+**CI smoke:** `.github/workflows/eval-harness-smoke.yml` runs on PRs that touch eval scripts, fixtures, **any `src/**` or `.pi/extensions/smart-router/**` change**, or the workflow. It executes `routing:eval-harness:smoke`, `routing:eval-harness:corpus-smoke`, and eval unit tests — fast, offline, no provider network calls. Job timeout stays at 10 minutes. The optional full-track nightly (`.github/workflows/twinrouterbench-full-nightly.yml`, `schedule` + `workflow_dispatch` only) is **not** on `pull_request` and must not be configured as a required status check — failures there do not gate PR CI or `release:functional-smoke`.
+
+**Calibration verify:** `.github/workflows/calibration-verify.yml` runs on PRs that touch calibration config/scripts (`config/routing-calibration.json*`, `config/p-success-weights.json`, `scripts/train-routing-calibration.ts`, `scripts/verify-routing-calibration.ts`, `scripts/lib/isotonic-calibrator.ts`, `scripts/lib/oats-centroid-refinement.ts`) **or calibration-consuming routing code** (`src/domain/routing/**`, `src/domain/pipeline/**`, `src/domain/types/**`, `src/cli/**`). It builds the library and verifies `config/routing-calibration.json.example` against benchmark prompts via `npm run routing:verify-calibration`.
 
 **TwinRouterBench static track:** import step-level router-visible prefixes with execution-verified target tiers (`track: "static"`). The adapter in `scripts/eval/twinrouterbench-adapter.ts` converts static track records into native eval fixtures for the three-track harness. See `docs/gemini-research.md` §9 for methodology context.
 
@@ -1178,6 +1187,21 @@ npm run routing:verify-benchmark-profiles
 
 Tag-triggered publish via GitHub Actions (requires `NPMSECRET` repository secret). pi.dev gallery listing syncs automatically from npm (`pi-package` keyword); no separate submit step.
 
+#### PR and pre-release quality gate set
+
+Operators should treat the following as the full gate set before merging routing changes and before tagging a release ([#135](https://github.com/beettlle/pi-smart-router/issues/135)):
+
+| Gate | Workflow / command | Runs when |
+|------|--------------------|-----------|
+| Build / typecheck / lint / coverage | `.github/workflows/ci.yml` (`npm run verify:ci`) | Every PR and push to `main` |
+| Eval harness smoke (offline) | `.github/workflows/eval-harness-smoke.yml` | PRs touching `scripts/eval/**`, `tests/eval/**`, **`src/**`**, **`.pi/extensions/smart-router/**`**, `package.json`, or the workflow |
+| Calibration verify | `.github/workflows/calibration-verify.yml` | PRs touching calibration config/scripts or calibration-consuming routing code (`src/domain/routing/**`, `src/domain/pipeline/**`, `src/domain/types/**`, `src/cli/**`) |
+| Benchmark profile smoke | `.github/workflows/benchmark-profile-refresh.yml` (`routing:verify-benchmark-profiles`) | PRs touching fixtures / ingest / profiles |
+| Pre-release functional smoke | `npm run release:check` (Tier 0: calibration `--skip-embed` + benchmark profiles + release-gate assertions) | Operator-run before `npm version` / tag |
+| TwinRouterBench full track | `.github/workflows/twinrouterbench-full-nightly.yml` | Nightly / manual only — **never** a required PR check |
+
+Required-check configuration for branch protection is a human-operator repo-settings decision; the workflow path filters above guarantee the jobs **run** on routing code edits regardless of which subset the operator marks required.
+
 **Scope composition:** use `/skill:router-release-operator` for themed release planning (not open-ended backlog cycles). **Patch** = docs + bugfixes only; **minor** = new capability (1–3 related issues under one theme). Budgets and audit rules: [`skills/router-release-operator/references/release-profiles.md`](skills/router-release-operator/references/release-profiles.md).
 
 **Tier 0 functional smoke** (`release:functional-smoke`) runs before tag publish and chains:

package/config/benchmark-profiles.json

@@ -7,8 +7,8 @@
       "livecodebench": "https://livecodebench.github.io/leaderboard.html",
       "bfcl": "https://gorilla.cs.berkeley.edu/leaderboard.html"
     },
-    "scrape_date": "2026-08-20",
-    "catalog_freeze_date": "2026-08-20"
+    "scrape_date": "2026-08-28",
+    "catalog_freeze_date": "2026-08-28"
   },
   "aliases": {
     "anthropic/claude-opus-4": "claude-opus-4-5",

package/config/operator-config.json.example

@@ -58,6 +58,12 @@
       "max_messages": 12,
       "max_tokens": 16384,
       "exclude_execution_history": true
+    },
+    "global_timeout_ms": 120000,
+    "sub_call_timeout_ms": 30000,
+    "_timeouts_documentation": {
+      "global_timeout_ms": "Global cap (ms) for the whole delegate stage; mirrors llm-use WORKER_GLOBAL_TIMEOUT. Default 120000 (SP-213, #120).",
+      "sub_call_timeout_ms": "Per-call cap (ms) for each delegate sub-call worker; mirrors llm-use WORKER_CALL_TIMEOUT. Default 30000 (SP-213, #120)."
     }
   },
   "local_zero": {

package/dist/domain/delegation/delegation-context.d.ts

@@ -2,7 +2,8 @@
  * Delegation context normalization — provider-agnostic replay identity fix.
  *
  * pi-ai transformMessages compares assistant message provider/api/model to the
- * target model. Virtual smart-router tags break isSameModel and strip replay
+ * target model. Foreign identities (virtual smart-router tags or any prior
+ * provider such as OpenAI/Anthropic/GLM) break isSameModel and strip replay
  * state (thoughtSignature, thinkingSignature, etc.).
  */
 import type { Api, AssistantMessage, Context, Message, Model } from '@earendil-works/pi-ai/compat';
@@ -35,11 +36,17 @@ export interface NormalizeDelegationContextOptions {
  */
 export declare function normalizeDelegationContext<TApi extends Api>(context: Context, targetModel: Model<TApi>, options?: NormalizeDelegationContextOptions): Context;
 /**
- * Repair Gemini tool-call replay for cross-model Google delegation.
+ * Repair Gemini tool-call replay for Google delegation targets.
  *
- * Call after {@link normalizeDelegationContext}. Aligns Google-origin assistant
- * identity to the delegation target and injects the thought-signature sentinel
- * when tool calls lack a captured signature.
+ * Call after {@link normalizeDelegationContext}. Aligns assistant identity to
+ * the delegation target and injects the thought-signature sentinel on every
+ * unsigned tool call, regardless of which provider produced the prior turn
+ * (Google, OpenAI, Anthropic, GLM, …). Captured signatures are preserved.
+ *
+ * Cross-provider repair (SP-231, #158): pi-ai strips replay state from any
+ * assistant message whose identity fails isSameModel, so a Gemini target
+ * would receive unsigned tool calls from non-Google turns and the Google API
+ * would reject the replay with a thought_signature error.
  */
 export declare function repairGeminiReplayContext<TApi extends Api>(context: Context, targetModel: Model<TApi>, sessionExecution?: ExecutionModel | null): Context;
 //# sourceMappingURL=delegation-context.d.ts.map

package/dist/domain/delegation/delegation-context.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"delegation-context.d.ts","sourceRoot":"","sources":["../../../src/domain/delegation/delegation-context.ts"],"names":[],"mappings":"AAAA;;;;;;;GAOG;AAEH,OAAO,KAAK,EACV,GAAG,EACH,gBAAgB,EAChB,OAAO,EACP,OAAO,EACP,KAAK,EACN,MAAM,8BAA8B,CAAC;AAEtC,OAAO,KAAK,EAAE,cAAc,EAAE,MAAM,uBAAuB,CAAC;AAE5D,eAAO,MAAM,uBAAuB,EAAG,cAAuB,CAAC;AAC/D,eAAO,MAAM,uBAAuB,EAAG,MAAe,CAAC;AAEvD;;;;;;;;;;GAUG;AACH,eAAO,MAAM,sCAAsC,EACjD,8CAAuD,CAAC;AAW1D,wBAAgB,uBAAuB,CAAC,QAAQ,EAAE,MAAM,EAAE,OAAO,EAAE,MAAM,GAAG,OAAO,CAElF;AAED,wBAAgB,wBAAwB,CAAC,IAAI,SAAS,GAAG,EAAE,KAAK,EAAE,KAAK,CAAC,IAAI,CAAC,GAAG,OAAO,CAetF;AAED,wBAAgB,8BAA8B,CAAC,OAAO,EAAE,gBAAgB,GAAG,OAAO,CAmBjF;AAED,wBAAgB,uBAAuB,CAAC,QAAQ,EAAE,SAAS,OAAO,EAAE,GAAG,OAAO,CA+B7E;AAoCD,MAAM,WAAW,iCAAiC;IAChD,QAAQ,CAAC,eAAe,CAAC,EAAE,OAAO,uBAAuB,CAAC;IAC1D,QAAQ,CAAC,gBAAgB,CAAC,EAAE,cAAc,GAAG,IAAI,CAAC;CACnD;AAED;;;GAGG;AACH,wBAAgB,0BAA0B,CAAC,IAAI,SAAS,GAAG,EACzD,OAAO,EAAE,OAAO,EAChB,WAAW,EAAE,KAAK,CAAC,IAAI,CAAC,EACxB,OAAO,CAAC,EAAE,iCAAiC,GAC1C,OAAO,CA2BT;AAED;;;;;;;;;;;;GAYG;AACH,wBAAgB,yBAAyB,CAAC,IAAI,SAAS,GAAG,EACxD,OAAO,EAAE,OAAO,EAChB,WAAW,EAAE,KAAK,CAAC,IAAI,CAAC,EACxB,gBAAgB,CAAC,EAAE,cAAc,GAAG,IAAI,GACvC,OAAO,CAwBT"}

package/dist/domain/delegation/delegation-context.js

@@ -2,7 +2,8 @@
  * Delegation context normalization — provider-agnostic replay identity fix.
  *
  * pi-ai transformMessages compares assistant message provider/api/model to the
- * target model. Virtual smart-router tags break isSameModel and strip replay
+ * target model. Foreign identities (virtual smart-router tags or any prior
+ * provider such as OpenAI/Anthropic/GLM) break isSameModel and strip replay
  * state (thoughtSignature, thinkingSignature, etc.).
  */
 export const VIRTUAL_ROUTER_PROVIDER = 'smart-router';
@@ -92,7 +93,7 @@ function rewriteAssistantIdentity(message, executionModel) {
         model: executionModel.id,
     };
 }
-function repairGoogleOriginAssistantMessage(message, targetExecution) {
+function repairAssistantForGoogleReplay(message, targetExecution) {
     const content = message.content.map((block) => {
         if (block.type !== 'toolCall') {
             return block;
@@ -134,11 +135,17 @@ export function normalizeDelegationContext(context, targetModel, options) {
     return { ...context, messages };
 }
 /**
- * Repair Gemini tool-call replay for cross-model Google delegation.
+ * Repair Gemini tool-call replay for Google delegation targets.
  *
- * Call after {@link normalizeDelegationContext}. Aligns Google-origin assistant
- * identity to the delegation target and injects the thought-signature sentinel
- * when tool calls lack a captured signature.
+ * Call after {@link normalizeDelegationContext}. Aligns assistant identity to
+ * the delegation target and injects the thought-signature sentinel on every
+ * unsigned tool call, regardless of which provider produced the prior turn
+ * (Google, OpenAI, Anthropic, GLM, …). Captured signatures are preserved.
+ *
+ * Cross-provider repair (SP-231, #158): pi-ai strips replay state from any
+ * assistant message whose identity fails isSameModel, so a Gemini target
+ * would receive unsigned tool calls from non-Google turns and the Google API
+ * would reject the replay with a thought_signature error.
  */
 export function repairGeminiReplayContext(context, targetModel, sessionExecution) {
     // Accepted for SP-128 call-site symmetry with normalizeDelegationContext; identity
@@ -156,10 +163,7 @@ export function repairGeminiReplayContext(context, targetModel, sessionExecution
         if (message.role !== 'assistant') {
             return message;
         }
-        if (!isGoogleOriginAssistantMessage(message)) {
-            return message;
-        }
-        return repairGoogleOriginAssistantMessage(message, targetExecution);
+        return repairAssistantForGoogleReplay(message, targetExecution);
     });
     return { ...context, messages };
 }

package/dist/domain/delegation/delegation-context.js.map

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