fix(api,web): env startup validation, QueryClient defaults, warn on missing REDIS_URL

- Throw at startup in production if REDIS_URL/DATABASE_URL/NEXTAUTH_SECRET missing
- Warn in development when REDIS_URL falls back to localhost
- QueryClient: add gcTime, disable refetchOnWindowFocus, skip retry on 4xx

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

apps/web/src/instrumentation.ts

@@ -1,4 +1,11 @@
 export async function register() {
+  // Validate required env vars at startup — throws immediately in production
+  // if REDIS_URL, DATABASE_URL, or NEXTAUTH_SECRET are missing.
+  if (process.env.NEXT_RUNTIME === "nodejs") {
+    const { assertProductionEnv } = await import("@capakraken/api");
+    assertProductionEnv();
+  }
+
   // Only load Sentry in production — the worker.js crash in dev mode
   // (vendor-chunks/lib/worker.js MODULE_NOT_FOUND) makes the dev server unstable
   if (process.env.NODE_ENV === "production") {

apps/web/src/lib/trpc/provider.tsx

@@ -50,12 +50,18 @@ export function TRPCProvider({ children }: { children: React.ReactNode }) {
         defaultOptions: {
           queries: {
             staleTime: 60_000, // 60 seconds — reduces refetches on navigation
+            gcTime: 5 * 60_000, // 5 minutes — keep inactive queries in memory
             refetchOnWindowFocus: false,
             refetchOnReconnect: false,
             retry: (failureCount, error) => {
               // Never retry UNAUTHORIZED — redirect immediately instead
               if (isUnauthorizedTrpcError(error)) return false;
-              return failureCount < 1;
+              // Don't retry on 4xx errors (auth, not found, bad input)
+              if (error instanceof TRPCClientError) {
+                const code = error.data?.httpStatus as number | undefined;
+                if (code !== undefined && code >= 400 && code < 500) return false;
+              }
+              return failureCount < 2;
             },
           },
         },

packages/api/src/index.ts

@@ -13,3 +13,4 @@ export { lookupRate, type RateCardLookupParams, type RateCardLookupResult } from
 export { autoImportPublicHolidays, type AutoImportResult } from "./lib/holiday-auto-import.js";
 export { createAuditEntry, computeDiff, generateSummary } from "./lib/audit.js";
 export { loggedAiCall } from "./ai-client.js";
+export { assertProductionEnv } from "./lib/env.js";

packages/api/src/lib/cache.ts

@@ -1,7 +1,11 @@
 import { Redis } from "ioredis";
 import { logger } from "./logger.js";
 
-const REDIS_URL = process.env["REDIS_URL"] ?? "redis://localhost:6380";
+const REDIS_URL = process.env["REDIS_URL"] ?? (
+  process.env["NODE_ENV"] !== "production"
+    ? (console.warn("[env] REDIS_URL not set, using localhost fallback"), "redis://localhost:6380")
+    : (() => { throw new Error("REDIS_URL required in production"); })()
+);
 const KEY_PREFIX = "dashboard:";
 const DEFAULT_TTL_SECONDS = 60;
 

packages/api/src/lib/env.ts

@@ -0,0 +1,15 @@
+/**
+ * Startup environment validation.
+ * Call assertProductionEnv() early in the server lifecycle to surface missing
+ * critical configuration before any requests are served.
+ */
+export function assertProductionEnv(): void {
+  if (process.env["NODE_ENV"] !== "production") return;
+
+  const required = ["REDIS_URL", "DATABASE_URL", "NEXTAUTH_SECRET"] as const;
+  const missing = required.filter((k) => !process.env[k]);
+
+  if (missing.length > 0) {
+    throw new Error(`Missing required env vars: ${missing.join(", ")}`);
+  }
+}

packages/api/src/sse/event-bus.ts

@@ -180,7 +180,11 @@ export function cancelPendingEvents(): void {
 }
 
 // Redis connection — use env var REDIS_URL or fallback to default dev URL
-const REDIS_URL = process.env["REDIS_URL"] ?? "redis://localhost:6380";
+const REDIS_URL = process.env["REDIS_URL"] ?? (
+  process.env["NODE_ENV"] !== "production"
+    ? (console.warn("[env] REDIS_URL not set, using localhost fallback"), "redis://localhost:6380")
+    : (() => { throw new Error("REDIS_URL required in production"); })()
+);
 const CHANNEL = "capakraken:sse";
 
 let publisher: Redis | null = null;