fix(stream): derive H.264 level from frame macroblocks, not height

Anamorphic 2.39:1 scaled to 1080 height = ~2586x1080 = 11016 MBs, busting
level 4.1's 8192-MB MaxFS -> nvenc "InitializeEncoder failed: Invalid Level"
(libx264: "frame MB size > level limit") -> 0 segments, session stalls. Most
4K rips are 2.39:1, so HLS playback was silently broken for them.

H264LevelForFrame(w,h) derives the level from the real macroblock count
(max of MB-tier and height-tier). hls.go computes output width and uses it.
16:9 unchanged; anamorphic bumps to 5.0 when needed. Discovered + verified
during the trickplay smoke.

internal/engine/hls.go

@@ -22,6 +22,7 @@ import (
 	"fmt"
 	"io"
 	"log"
+	"math"
 	"net/http"
 	"os"
 	"os/exec"
@@ -1184,11 +1185,14 @@ func buildHLSFFmpegArgsAt(cfg HLSSessionConfig, probe *StreamProbe, tmpDir strin
 		// per session start, polluting logs even though encode succeeds.
 		args = append(args, "-vaapi_device", "/dev/dri/renderD128")
 	}
-	// Derive H.264 level from the actual output height. A fixed "4.0" caps the
+	// Derive H.264 level from the actual output FRAME (width × height), not just
-	// encoder at 1080p — anything taller (1440p, 4K source on quality=original)
+	// height. A fixed "4.0" caps the encoder at 1080p; deriving by height alone
-	// fails libx264 with "frame MB size > level limit" and emits unplayable
+	// still under-levels anamorphic content — a 2.39:1 source scaled to 1080
-	// segments. The output height matches qcap.MaxHeight when the source is
+	// height is ~2586×1080 = 11016 MBs, busting level 4.1's 8192-MB cap, which
-	// downscaled, otherwise probe.Height (already populated by ffprobe).
+	// fails the encode ("Invalid Level" on nvenc, "frame MB size > level limit"
+	// on libx264) and stalls the session. The output height matches qcap.MaxHeight
+	// when the source is downscaled, otherwise probe.Height; the output width is
+	// the source width scaled by the same factor (the filter chain preserves AR).
 	qcap := resolveQualityCap(cfg.Quality)
 	outputHeight := qcap.MaxHeight
 	if outputHeight == 0 {
@@ -1197,7 +1201,11 @@ func buildHLSFFmpegArgsAt(cfg HLSSessionConfig, probe *StreamProbe, tmpDir strin
 	if outputHeight == 0 || (probe.Height > 0 && probe.Height < outputHeight) {
 		outputHeight = probe.Height
 	}
-	args = append(args, "-profile:v", "main", "-level:v", H264LevelForHeight(outputHeight))
+	outputWidth := probe.Width
+	if probe.Height > 0 && outputHeight != probe.Height {
+		outputWidth = int(math.Round(float64(probe.Width) * float64(outputHeight) / float64(probe.Height)))
+	}
+	args = append(args, "-profile:v", "main", "-level:v", H264LevelForFrame(outputWidth, outputHeight))
 
 	// Bitrate must match the level libx264 actually picks for outputHeight,
 	// not the qcap target for the user's requested label. If a user asks for

internal/engine/hwaccel.go

@@ -271,3 +271,60 @@ func H264LevelForHeight(height int) string {
 		return "6.0"
 	}
 }
+
+// h264LevelRank orders level strings so callers can pick the higher of two.
+var h264LevelRank = map[string]int{
+	"3.0": 30, "3.1": 31, "3.2": 32,
+	"4.0": 40, "4.1": 41, "4.2": 42,
+	"5.0": 50, "5.1": 51, "6.0": 60,
+}
+
+// levelForMacroblocks returns the lowest H.264 level whose MaxFS (frame size in
+// macroblocks) covers `mbs`. The height-based H264LevelForHeight tier is correct
+// for 16:9, but anamorphic content (2.39:1 cinemascope) scaled to a given height
+// has a much wider frame: a 2.39:1 source downscaled to 1080 height becomes
+// ~2586×1080 = 11016 MBs, which busts level 4.1's 8192-MB MaxFS. ffmpeg then
+// fails the encode — libx264 with "frame MB size > level limit", h264_nvenc with
+// "InitializeEncoder failed: invalid param (8): Invalid Level" — and emits zero
+// packets (the whole HLS session stalls at "preparando sesión"). MaxFS values
+// from the H.264 spec, Table A-1.
+func levelForMacroblocks(mbs int) string {
+	switch {
+	case mbs <= 1620:
+		return "3.0"
+	case mbs <= 3600:
+		return "3.1"
+	case mbs <= 5120:
+		return "3.2"
+	case mbs <= 8192: // levels 4.0 and 4.1 share MaxFS 8192; pick 4.1 for headroom
+		return "4.1"
+	case mbs <= 8704:
+		return "4.2"
+	case mbs <= 22080:
+		return "5.0"
+	case mbs <= 36864:
+		return "5.1"
+	default:
+		return "6.0"
+	}
+}
+
+// H264LevelForFrame returns the lowest H.264 level that satisfies BOTH the
+// height-derived tier (which carries macroblock-rate / fps headroom) and the
+// actual frame's macroblock count (which catches anamorphic frames that are far
+// wider than 16:9 at a given height). Use this instead of H264LevelForHeight
+// wherever the output width is known — it never under-levels an ultra-wide
+// frame, and for 16:9 content it returns exactly what H264LevelForHeight does.
+func H264LevelForFrame(width, height int) string {
+	byHeight := H264LevelForHeight(height)
+	if width <= 0 || height <= 0 {
+		return byHeight
+	}
+	// Macroblocks are 16×16; partial blocks at the edge still count (ceil).
+	mbs := ((width + 15) / 16) * ((height + 15) / 16)
+	byMB := levelForMacroblocks(mbs)
+	if h264LevelRank[byMB] > h264LevelRank[byHeight] {
+		return byMB
+	}
+	return byHeight
+}

internal/engine/hwaccel_test.go

@@ -81,12 +81,12 @@ func TestResolveEncoderProfileHonoursConfiguredPreset(t *testing.T) {
 		configured string
 		wantPreset string
 	}{
-		{HWAccelNone, "ultrafast", "ultrafast"},  // libx264 honours
+		{HWAccelNone, "ultrafast", "ultrafast"}, // libx264 honours
-		{HWAccelNone, "medium", "medium"},        // libx264 honours
+		{HWAccelNone, "medium", "medium"},       // libx264 honours
-		{HWAccelNVENC, "p1", "p3"},               // NVENC ignores, sticks to p3
+		{HWAccelNVENC, "p1", "p3"},              // NVENC ignores, sticks to p3
-		{HWAccelNVENC, "veryfast", "p3"},         // NVENC ignores libx264 vocab
+		{HWAccelNVENC, "veryfast", "p3"},        // NVENC ignores libx264 vocab
-		{HWAccelQSV, "veryslow", "veryfast"},     // QSV ignores, sticks to veryfast
+		{HWAccelQSV, "veryslow", "veryfast"},    // QSV ignores, sticks to veryfast
-		{HWAccelVideoToolbox, "veryfast", ""},    // VideoToolbox has no preset
+		{HWAccelVideoToolbox, "veryfast", ""},   // VideoToolbox has no preset
 	}
 	for _, tc := range cases {
 		got := ResolveEncoderProfile(tc.hw, tc.configured)
@@ -154,3 +154,33 @@ func TestHWAccelDiagnosticLogLineSoftwareButEncodersFound(t *testing.T) {
 	}
 }
 
+func TestH264LevelForFrame(t *testing.T) {
+	cases := []struct {
+		name          string
+		width, height int
+		want          string
+	}{
+		// 16:9 must match the height-only helper exactly (no regression).
+		{"720p 16:9", 1280, 720, "4.0"},
+		{"1080p 16:9", 1920, 1080, "4.1"},
+		{"1440p 16:9", 2560, 1440, "5.0"},
+		{"2160p 16:9", 3840, 2160, "5.1"},
+		// Anamorphic 2.39:1 at 1080 height — the regression: ~2586×1080 = 11016
+		// MBs busts level 4.1 (8192 MaxFS); must bump to 5.0.
+		{"1080h anamorphic 2.39:1", 2586, 1080, "5.0"},
+		// Anamorphic 720 height (1728×720 = 4860 MBs) still fits the 4.0 the
+		// height floor already picks for fps headroom.
+		{"720h anamorphic 2.4:1", 1728, 720, "4.0"},
+		// Source 4K anamorphic (3840×1604) encoded at source: 24240 MBs → 5.1.
+		{"4K anamorphic source", 3840, 1604, "5.1"},
+		// Width unknown → fall back to the height-only tier.
+		{"width unknown", 0, 1080, "4.1"},
+	}
+	for _, c := range cases {
+		t.Run(c.name, func(t *testing.T) {
+			if got := H264LevelForFrame(c.width, c.height); got != c.want {
+				t.Errorf("H264LevelForFrame(%d,%d) = %q, want %q", c.width, c.height, got, c.want)
+			}
+		})
+	}
+}