Guard error.message with rescue in LLM failed-usage recording (#1144)

* Initial plan

* Fix nil references in Recording failed LLM usage code paths

Co-authored-by: jjmata <187772+jjmata@users.noreply.github.com>

* Replace error&.message with rescue-guarded safe_error_message helper

error&.message only guards against nil; it still raises when the error
object's .message implementation itself throws (e.g. OpenAI errors that
call data on nil). Replace with a safe_error_message helper that wraps
error&.message in a rescue block, returning a descriptive fallback
string on secondary failures. Apply the helper in both record_usage_error
(usage_recorder.rb) and record_llm_usage (openai.rb), including the
regex branch of extract_http_status_code in both files.

Co-authored-by: jjmata <187772+jjmata@users.noreply.github.com>

---------

Co-authored-by: copilot-swe-agent[bot] <198982749+Copilot@users.noreply.github.com>
Co-authored-by: jjmata <187772+jjmata@users.noreply.github.com>

app/models/provider/openai.rb

@@ -538,7 +538,7 @@ class Provider::Openai < Provider
 
       # For error cases, record with zero tokens
       if error.present?
-        Rails.logger.info("Recording failed LLM usage - Error: #{error.message}")
+        Rails.logger.info("Recording failed LLM usage - Error: #{safe_error_message(error)}")
 
         # Extract HTTP status code if available from the error
         http_status_code = extract_http_status_code(error)
@@ -553,7 +553,7 @@ class Provider::Openai < Provider
           total_tokens: 0,
           estimated_cost: nil,
           metadata: {
-            error: error.message,
+            error: safe_error_message(error),
             http_status_code: http_status_code
           }
         )
@@ -614,11 +614,17 @@ class Provider::Openai < Provider
         error.status_code
       elsif error.respond_to?(:response) && error.response.respond_to?(:code)
         error.response.code.to_i
-      elsif error.message =~ /(\d{3})/
+      elsif safe_error_message(error) =~ /(\d{3})/
         # Extract 3-digit HTTP status code from error message
         $1.to_i
       else
         nil
       end
     end
+
+    def safe_error_message(error)
+      error&.message
+    rescue => e
+      "(message unavailable: #{e.class})"
+    end
 end

app/models/provider/openai/concerns/usage_recorder.rb

@@ -47,15 +47,15 @@ module Provider::Openai::Concerns::UsageRecorder
 
     # Records failed LLM usage for a family with error details
     def record_usage_error(model_name, operation:, error:, metadata: {})
-      return unless family
+      return unless family && error
 
-      Rails.logger.info("Recording failed LLM usage - Operation: #{operation}, Error: #{error.message}")
+      Rails.logger.info("Recording failed LLM usage - Operation: #{operation}, Error: #{safe_error_message(error)}")
 
       # Extract HTTP status code if available from the error
       http_status_code = extract_http_status_code(error)
 
       error_metadata = metadata.merge(
-        error: error.message,
+        error: safe_error_message(error),
         http_status_code: http_status_code
       )
 
@@ -86,11 +86,17 @@ module Provider::Openai::Concerns::UsageRecorder
         error.status_code
       elsif error.respond_to?(:response) && error.response.respond_to?(:code)
         error.response.code.to_i
-      elsif error.message =~ /(\d{3})/
+      elsif safe_error_message(error) =~ /(\d{3})/
         # Extract 3-digit HTTP status code from error message
         $1.to_i
       else
         nil
       end
     end
+
+    def safe_error_message(error)
+      error&.message
+    rescue => e
+      "(message unavailable: #{e.class})"
+    end
 end