fix(knowledge): withdraw a queued generation when its Search KB turns dormant

apps/sim/lib/knowledge/__integration__/dormant-search-processing.integration.ts

@@ -95,4 +95,68 @@ describe('dormant Search document processing', () => {
       .where(eq(document.id, documentId))
     expect(stored.status).toBe('pending')
   })
+
+  it('withdraws its own queued generation and refunds the charged attempt once', async () => {
+    const queuedAt = new Date('2026-09-29T00:00:00.000Z')
+    const token = generateId()
+    await db
+      .update(document)
+      .set({ processingQueueToken: token, processingQueuedAt: queuedAt, processingAttempts: 2 })
+      .where(eq(document.id, documentId))
+    const attempt = {
+      chargedAtDispatch: true,
+      processingQueueToken: token,
+      processingQueuedAt: queuedAt,
+    }
+    for (const _ of [1, 2]) {
+      expect(
+        await processDocumentAsync(
+          ids.knowledgeBaseId,
+          documentId,
+          source,
+          {},
+          undefined,
+          'pass',
+          attempt
+        )
+      ).toEqual({ outcome: 'skipped', reason: 'unavailable' })
+    }
+    const [stored] = await db
+      .select({
+        status: document.processingStatus,
+        token: document.processingQueueToken,
+        queuedAt: document.processingQueuedAt,
+        attempts: document.processingAttempts,
+      })
+      .from(document)
+      .where(eq(document.id, documentId))
+    expect(stored).toEqual({ status: 'pending', token, queuedAt: null, attempts: 1 })
+  })
+
+  it('leaves a newer queued generation untouched, even under a reused token', async () => {
+    const queuedAt = new Date('2026-09-29T01:00:00.000Z')
+    const newer = generateId()
+    await db
+      .update(document)
+      .set({ processingQueueToken: newer, processingQueuedAt: queuedAt, processingAttempts: 1 })
+      .where(eq(document.id, documentId))
+    await processDocumentAsync(ids.knowledgeBaseId, documentId, source, {}, undefined, 'pass', {
+      chargedAtDispatch: true,
+      processingQueueToken: generateId(),
+    })
+    await processDocumentAsync(ids.knowledgeBaseId, documentId, source, {}, undefined, 'pass', {
+      chargedAtDispatch: true,
+      processingQueueToken: newer,
+      processingQueuedAt: new Date('2026-09-29T00:30:00.000Z'),
+    })
+    const [stored] = await db
+      .select({
+        token: document.processingQueueToken,
+        queuedAt: document.processingQueuedAt,
+        attempts: document.processingAttempts,
+      })
+      .from(document)
+      .where(eq(document.id, documentId))
+    expect(stored).toEqual({ token: newer, queuedAt, attempts: 1 })
+  })
 })

apps/sim/lib/knowledge/documents/service.ts

@@ -1673,6 +1673,34 @@ export async function processDocumentAsync(
       .limit(1)
 
     if (contextRows[0] && !requiresConnectorIndexing(contextRows[0].isSearchIndex)) {
+      /**
+       * A generation queued before its KB went dormant (e.g. legacy index adoption) gives back its
+       * stamp and charged attempt, as `clearDocumentsQueued` does; the token stays as the owner.
+       */
+      if (attemptContext?.processingQueueToken || attemptContext?.processingQueuedAt) {
+        await db
+          .update(document)
+          .set({
+            processingQueuedAt: null,
+            ...(attemptContext.chargedAtDispatch
+              ? { processingAttempts: sql`GREATEST(${document.processingAttempts} - 1, 0)` }
+              : {}),
+          })
+          .where(
+            and(
+              eq(document.id, documentId),
+              eq(document.processingStatus, 'pending'),
+              /**
+               * Only the exact stamp this payload was queued with: a duplicate of an already
+               * withdrawn generation, or a newer stamp under a reused token, is left alone.
+               */
+              attemptContext.processingQueuedAt
+                ? eq(document.processingQueuedAt, attemptContext.processingQueuedAt)
+                : isNotNull(document.processingQueuedAt),
+              ...queueGenerationConditions(attemptContext)
+            )
+          )
+      }
       return { outcome: 'skipped', reason: 'unavailable' }
     }
     if (contextRows.length === 0) {