"If it had reached a resource limit an error would be logged. So, if there's no errors it either isn't hitting a resource limit or you're looking in the wrong place." Right. I looked in the likely places as mentioned (apache log, mysql log)....no messages. Not sure where else to look. I don't have root access to the production server, but my sysadmin is amazing and actually does what I ask when I know what to ask.
The question is now moot. I reran the upgrade .... it took four tries on the test system and two tries on the production system, but it did eventually get through all of the the question category rebuilds in each environment, and then finished the upgrade for some 380+ Moodle core modules and two plugins without any hitches. My sense is that something somewhere was timing out. Since I was doing this through a remote browser, it is even theoretically possible that my browser connection was interrupted. I'm assuming if that was the problem, there would be no error messages ... so it sort of makes sense.
At the moment, everything on both test and production look good, and this means (unfortunately for the analysis) that I'm not in a position to figure out why there was an issue in the first place.
I really appreciate the feedback. I know you all have a life and other problems, and it is wonderful to me (especially in the brittle environment of civility in which we now dwell) that you would take even a few moments to consider my issue and try to help. I hope you have the most wonderful day!
Also: I do have the php intl extension running on my Mac. When I realized that the El Capitan PHP wasn't at 7.0+ and I wasn't ready to upgrade to High Sierra (which is) since I'll lose some apps I like, I installed PHP 5.6 and 7.1.18 from homebrew, and then installed homebrew Apache 2.2 so I could tweek it. After much consternation I got the El Capitan PHP and Apache turned off and everything set so that the Mac initializes and uses the homebrew environment on reboot. I don't remember doing anything special in configuring PHP 7 beyond the basics to get it working, so the homebrew install included the PHP intl as part of the installation. If you have specific questions, I can dig into my upgrade notes to find out. Right now, my Mac test and support environments mimic my gentoo Linux test and production environments perfectly -- same data, same results. Back to actually writing quizzes for my courses....