Add internal exception handling to _send_error_notification

src/kai/triage.py

@@ -791,19 +791,12 @@ async def triage_issue(
         # notification, so just log and bail.
         if metadata is None:
             return
-        try:
-            await _send_error_notification(
-                metadata,
-                str(exc),
-                webhook_port,
-                webhook_secret,
-            )
-        except Exception:
-            log.exception(
-                "Failed to send failure notification for %s#%d",
-                metadata.repo,
-                metadata.number,
-            )
+        await _send_error_notification(
+            metadata,
+            str(exc),
+            webhook_port,
+            webhook_secret,
+        )
 
 
 async def _send_error_notification(
@@ -817,6 +810,7 @@ async def _send_error_notification(
 
     Called when the triage pipeline fails at any point. Sends a brief
     message so the user knows something went wrong and can check the logs.
+    Never raises - logs a warning on failure and returns.
 
     Args:
         metadata: Issue metadata for context.
@@ -831,12 +825,20 @@ async def _send_error_notification(
         "X-Webhook-Secret": webhook_secret,
     }
 
-    async with (
-        aiohttp.ClientSession() as session,
-        session.post(url, json={"text": text}, headers=headers) as resp,
-    ):
-        if resp.status != 200:
-            log.warning(
-                "send-message API returned %d for triage error notification",
-                resp.status,
-            )
+    try:
+        async with (
+            aiohttp.ClientSession() as session,
+            session.post(url, json={"text": text}, headers=headers) as resp,
+        ):
+            if resp.status != 200:
+                log.warning(
+                    "send-message API returned %d for triage error notification",
+                    resp.status,
+                )
+    except Exception:
+        log.warning(
+            "Failed to send triage error notification for %s#%d",
+            metadata.repo,
+            metadata.number,
+            exc_info=True,
+        )

tests/test_triage.py

@@ -11,6 +11,7 @@
     IssueMetadata,
     _parse_triage_json,
     _sanitize_search_query,
+    _send_error_notification,
     apply_triage,
     build_triage_prompt,
     extract_issue_metadata,
@@ -778,3 +779,80 @@ async def mock_exec(*args, **kwargs):
         mock_session.post.assert_called_once()
         body = mock_session.post.call_args[1]["json"]
         assert "failed" in body["text"].lower()
+
+
+# ── _send_error_notification ──────────────────────────────────────
+
+
+class TestSendErrorNotification:
+    """Verify _send_error_notification never raises."""
+
+    @pytest.mark.asyncio
+    async def test_does_not_raise_on_connection_error(self):
+        """Connection failure is caught and logged, not raised."""
+        metadata = IssueMetadata(
+            repo="owner/repo",
+            number=42,
+            title="Test issue",
+            body="body",
+            author="user",
+            url="https://github.com/owner/repo/issues/42",
+            labels=[],
+        )
+
+        mock_session = AsyncMock()
+        mock_session.post = AsyncMock(side_effect=ConnectionError("refused"))
+        mock_session.__aenter__ = AsyncMock(return_value=mock_session)
+        mock_session.__aexit__ = AsyncMock(return_value=False)
+
+        with patch("kai.triage.aiohttp.ClientSession", return_value=mock_session):
+            # Should not raise
+            await _send_error_notification(metadata, "test error", 8080, "secret")
+
+    @pytest.mark.asyncio
+    async def test_does_not_raise_on_timeout(self):
+        """Timeout is caught and logged, not raised."""
+
+        metadata = IssueMetadata(
+            repo="owner/repo",
+            number=42,
+            title="Test issue",
+            body="body",
+            author="user",
+            url="https://github.com/owner/repo/issues/42",
+            labels=[],
+        )
+
+        mock_session = AsyncMock()
+        mock_session.post = AsyncMock(side_effect=TimeoutError())
+        mock_session.__aenter__ = AsyncMock(return_value=mock_session)
+        mock_session.__aexit__ = AsyncMock(return_value=False)
+
+        with patch("kai.triage.aiohttp.ClientSession", return_value=mock_session):
+            await _send_error_notification(metadata, "test error", 8080, "secret")
+
+    @pytest.mark.asyncio
+    async def test_logs_warning_on_failure(self, caplog):
+        """A warning is logged when the notification fails."""
+        metadata = IssueMetadata(
+            repo="owner/repo",
+            number=42,
+            title="Test issue",
+            body="body",
+            author="user",
+            url="https://github.com/owner/repo/issues/42",
+            labels=[],
+        )
+
+        mock_session = AsyncMock()
+        mock_session.post = AsyncMock(side_effect=RuntimeError("boom"))
+        mock_session.__aenter__ = AsyncMock(return_value=mock_session)
+        mock_session.__aexit__ = AsyncMock(return_value=False)
+
+        with (
+            patch("kai.triage.aiohttp.ClientSession", return_value=mock_session),
+            caplog.at_level("WARNING", logger="kai.triage"),
+        ):
+            await _send_error_notification(metadata, "test error", 8080, "secret")
+
+        assert "Failed to send triage error notification" in caplog.text