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Jonathan KaiserandClaude Sonnet 5 b9b5a7c58b feat: verify AI configuration and provider liveness from worker processes
Closes #3169.

The AI status page (#3145, PR #3155) proves only that the `web` process
resolved a valid-looking configuration and can reach the configured
provider from its own network context. Most AI workloads -- assistant
responses, PDF processing, embeddings, auto-categorization, and merchant
detection -- actually run in Sidekiq `worker` processes, which can differ
from `web` in environment, DNS, proxy rules, network policy, or even
loaded credentials (workload-specific overrides, an updated Secret without
a pod restart, `web` recreated without `worker`). A passing web check says
nothing about whether a worker can do the same.

## What this adds

`WorkerAiHealthCheckJob`, queued on demand from a new "Verify worker
configuration" button on System health -> AI status. It runs the same
bounded, non-destructive probes `AiHealth` already runs, but from inside
whichever Sidekiq worker process dequeues it, and records the result via
`WorkerAiHealth`: process identity (hostname:pid), checked-at time, a
non-secret configuration fingerprint (effective provider, model, redacted
endpoint, vector-store adapter/embedding config), and probe outcomes.

The AI status tab lists every recorded result -- most recent first, kept
for `WorkerAiHealth::RETENTION` (15 minutes) -- each labeled with a status
pill (`Passing` / `Failing` / `Stale`, the last once older than
`STALE_AFTER`) and a configuration pill comparing it against the web
snapshot (`Matches web` / `Differs from web`), with a failure-reason list
reusing the existing failure-code translations when a probe failed.

## Implementation constraints from the issue, addressed directly

- **Cannot reuse a web-cached probe result, or vice versa.** `AiHealth.new`
  gained an injectable `probe_cache:` (default `Rails.cache`, matching
  today's behavior). The worker job passes a fresh
  `ActiveSupport::Cache::NullStore` instead, so every worker check is a
  live call that neither reads a web-cached entry nor leaves one behind.
- **A single job only verifies one worker.** Documented on the button
  (`coverage_notice`) and in the docs: with multiple replicas, a passing
  result names one process, not the fleet. Queuing again samples another.
- **Never persists or displays a raw credential.** `WorkerAiHealth::Snapshot`
  only carries redacted endpoints (AiHealth already redacts these before
  they reach the job) and provider/model/status fields -- there is no field
  for a token to occupy. A structural test asserts this stays true.
- **Failures land in both places an operator already checks.** Same
  destinations as `AiHealth::Probe`'s own failures: `Rails.logger` and
  `DebugLogEntry` (new `ai_health_worker` category), tagged with the
  process identity.
- **Results carry a clear status**, including the `pending` case implicitly
  (no result yet renders an explanatory empty state) and `stale` for a
  result whose process may no longer reflect current state.
- **DB-backed vs ENV-backed settings are labeled.** A new info block next
  to the worker results explains which UI settings propagate automatically
  (rails-settings-cached invalidates the shared cache on write) versus
  which require restarting/recreating both `web` and `worker`.

## What this deliberately doesn't do

Full-fleet coverage (every process publishing a periodic fingerprint) --
the issue lists this under "Other options to consider," not the acceptance
criteria, and Sidekiq's normal dispatch doesn't target every process
without an explicit per-process coordination mechanism. This PR implements
the on-demand, single-check design the acceptance criteria actually
describes ("An administrator can request an asynchronous worker-side
check", "does not imply full-fleet coverage"); periodic fleet-wide
publishing is a natural follow-up if operators need it.

## Testing

- `WorkerAiHealth`: recording/reading, same-process replacement vs.
  cross-process coexistence, MAX_RESULTS bounding, staleness, status
  derivation (failure codes / component statuses / function-calling
  refusal), `matches_web?` comparison, and the credential-field structural
  guard.
- `WorkerAiHealthCheckJob`: records a passing/failing snapshot naming this
  process, writes failures to Rails.logger + DebugLogEntry (and only on
  failure), never leaks the access token, and -- the defining property --
  is proven to construct `AiHealth.new` with an isolated `NullStore`
  rather than the shared web-facing cache.
- `Admin::SystemHealthController`: empty state, a rendered result with
  matching/mismatched configuration, a failing result's failure reason, a
  stale result, the `verify_worker_ai` action enqueuing the job and
  redirecting with a flash notice, and that non-super-admins and
  unauthenticated requests cannot trigger it.

I could not run the Rails test suite in this environment (no working
Ruby/Bundler toolchain available locally -- Ruby 2.6 system Ruby vs. the
project's required 3.4.9, no way to install without sudo/Docker access).
Every file was checked with `ruby -c`, YAML files with `YAML.load_file`,
and the ERB view with `ERB.new(...).src`, plus careful manual tracing of
each test against the production code paths it exercises, but CI should
be treated as the first real run of this suite per the repository's own
guidance for exactly this situation.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01A9494Pxh4LZKnNLTGfFXPw
2026-09-02 07:15:54 +02:00
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