fix(queue): stamp console.error payloads as level error

Twenty-four queue failure logs used console.error with an explicit
level:"warn", which made forwardStructuredLogToSentry treat real
failures as warnings. Align them with the sink and the other
console.error call sites in the same files.

Closes #7806

Co-authored-by: Cursor <cursoragent@cursor.com>

Author: bohdansolovie

src/queue/ai-review-orchestration.ts

@@ -880,7 +880,7 @@ export async function runAiReviewForAdvisory(
   } catch (error) {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "ai_review_failed",
         repository: args.repoFullName,
         pullNumber: args.pr.number,

src/queue/processors.ts

@@ -805,7 +805,7 @@ export async function buildContributorDecisionPacks(
       /* v8 ignore next -- defensive per-login isolation; the log-and-continue path is not exercised in tests */
       console.error(
         JSON.stringify({
-          level: "warn",
+          level: "error",
           event: "decision_pack_login_failed",
           login: contributorLogin,
           error: errorMessage(error),
@@ -1474,7 +1474,7 @@ export async function sweepRepoRegate(
   ).catch((error) => {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "sweep_mark_regated_failed",
         repository: repoFullName,
         error: errorMessage(error),
@@ -1775,7 +1775,7 @@ export async function sweepRepoBacklogConvergence(
   ).catch((error) => {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "backlog_convergence_mark_regated_failed",
         repository: repoFullName,
         error: errorMessage(error),
@@ -1919,7 +1919,7 @@ export async function regatePullRequest(
     }
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "sweep_rereview_failed",
         deliveryId,
         repository: repoFullName,
@@ -3584,7 +3584,7 @@ export async function reReviewStoredPullRequest(
     if (isGitHubRateLimitedError(error) || isRetryableJobError(error)) throw error;
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "pr_public_surface_failed",
         deliveryId,
         repository: repoFullName,
@@ -3618,7 +3618,7 @@ export async function reReviewStoredPullRequest(
   ).catch((error) => {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "agent_maintenance_failed",
         deliveryId,
         repository: repoFullName,
@@ -5139,7 +5139,7 @@ async function processContributorEvidenceLogins(
       /* v8 ignore next -- defensive per-login isolation; the log-and-continue path is not exercised in tests */
       console.error(
         JSON.stringify({
-          level: "warn",
+          level: "error",
           event: "contributor_evidence_login_failed",
           login: contributorLogin,
           error: errorMessage(error),
@@ -6388,7 +6388,7 @@ async function handlePullRequestWebhookEvent(
           if (isGitHubRateLimitedError(error) || isRetryableJobError(error)) throw error;
           console.error(
             JSON.stringify({
-              level: "warn",
+              level: "error",
               event: "pr_public_surface_failed",
               deliveryId,
               repository: payload.repository?.full_name,
@@ -6426,7 +6426,7 @@ async function handlePullRequestWebhookEvent(
           /* v8 ignore next -- best-effort: auto-maintain failures are logged, never surfaced to the gate. */
           console.error(
             JSON.stringify({
-              level: "warn",
+              level: "error",
               event: "agent_maintenance_failed",
               deliveryId,
               repository: repoFullName,
@@ -6457,7 +6457,7 @@ async function handlePullRequestWebhookEvent(
           /* v8 ignore next -- best-effort: a reputation-record failure is logged, never surfaced to the gate. */
           console.error(
             JSON.stringify({
-              level: "warn",
+              level: "error",
               event: "reputation_record_failed",
               deliveryId,
               repository: repoFullName,
@@ -6483,7 +6483,7 @@ async function handlePullRequestWebhookEvent(
         /* v8 ignore next -- best-effort: a RAG re-index enqueue failure is logged, never surfaced to the gate. */
         console.error(
           JSON.stringify({
-            level: "warn",
+            level: "error",
             event: "rag_reindex_enqueue_failed",
             deliveryId,
             repository: repoFullName,
@@ -6508,7 +6508,7 @@ async function handlePullRequestWebhookEvent(
         /* v8 ignore next -- best-effort: a sibling re-gate enqueue failure is logged, never surfaced to the gate. */
         console.error(
           JSON.stringify({
-            level: "warn",
+            level: "error",
             event: "sibling_regate_enqueue_failed",
             deliveryId,
             repository: repoFullName,
@@ -6612,7 +6612,7 @@ async function handleIssueWebhookEvent(
         /* v8 ignore next -- best-effort: an issue-cap enforcement failure is logged, never surfaced to the webhook. */
         console.error(
           JSON.stringify({
-            level: "warn",
+            level: "error",
             event: "contributor_issue_cap_failed",
             deliveryId,
             repository: payload.repository?.full_name,
@@ -7013,7 +7013,7 @@ async function resolvePullRequestFilesForReview(
     /* v8 ignore next -- fail-safe: an inline fetch failure degrades to the empty stored rows (byte-identical to pre-fix). */
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "review_files_inline_fetch_failed",
         repository: args.repoFullName,
         pullNumber: args.pullNumber,
@@ -7479,7 +7479,7 @@ export async function runLinkedIssueSatisfactionForAdvisory(
   } catch (error) {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "linked_issue_satisfaction_failed",
         repository: args.repoFullName,
         pullNumber: args.pr.number,
@@ -7557,7 +7557,7 @@ export async function runContentLaneDeliverableCheckForAdvisory(
      * calls (e.g. a DB-backed cache layer) degrades to "no finding" instead of an unhandled rejection. */
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "content_lane_deliverable_check_failed",
         repository: args.repoFullName,
         pullNumber: primaryIssueNumber,
@@ -9058,12 +9058,12 @@ async function maybePublishPrPublicSurface(
     // Stamp the head SHA only after every required public surface for this repo completed. For gate-enabled repos,
     // a comment/label without a finalized Orb gate check is incomplete and must stay repair-visible to the sweep.
     await markPullRequestSurfacePublished(env, repoFullName, pr.number, advisory.headSha).catch((error) => {
-      console.error(JSON.stringify({ level: "warn", event: "surface_published_mark_failed", repoFullName, pullNumber: pr.number, error: errorMessage(error) }));
+      console.error(JSON.stringify({ level: "error", event: "surface_published_mark_failed", repoFullName, pullNumber: pr.number, error: errorMessage(error) }));
     });
     // #regate-churn: mark the AI review row for THIS head+fingerprint as durably published (a no-op when no fresh
     // row was written this pass -- e.g. the frozen-reuse path above, or AI review off/skipped entirely).
     await markAiReviewPublished(env, repoFullName, pr.number, advisory.headSha).catch((error) => {
-      console.error(JSON.stringify({ level: "warn", event: "ai_review_published_mark_failed", repoFullName, pullNumber: pr.number, error: errorMessage(error) }));
+      console.error(JSON.stringify({ level: "error", event: "ai_review_published_mark_failed", repoFullName, pullNumber: pr.number, error: errorMessage(error) }));
     });
     return gateEvaluation;
   };
@@ -10374,7 +10374,7 @@ async function maybePublishPrPublicSurface(
             }).catch((error) => {
               console.error(
                 JSON.stringify({
-                  level: "warn",
+                  level: "error",
                   event: "gate_check_summary_upsert_failed",
                   repoFullName,
                   pullNumber: pr.number,
@@ -10466,7 +10466,7 @@ async function maybePublishPrPublicSurface(
           }).catch((error) => {
             console.error(
               JSON.stringify({
-                level: "warn",
+                level: "error",
                 event: "gate_check_summary_upsert_failed",
                 repoFullName,
                 pullNumber: pr.number,
@@ -10512,7 +10512,7 @@ async function maybePublishPrPublicSurface(
               }).catch((error) => {
                 console.error(
                   JSON.stringify({
-                    level: "warn",
+                    level: "error",
                     event: "gate_check_summary_upsert_failed",
                     repoFullName,
                     pullNumber: pr.number,
@@ -10554,7 +10554,7 @@ async function maybePublishPrPublicSurface(
             }).catch((error) => {
               console.error(
                 JSON.stringify({
-                  level: "warn",
+                  level: "error",
                   event: "gate_check_summary_upsert_failed",
                   repoFullName,
                   pullNumber: pr.number,

src/queue/slop-detection.ts

@@ -172,7 +172,7 @@ export async function runAiSlopForAdvisory(
   } catch (error) {
     console.error(
       JSON.stringify({
-        level: "warn",
+        level: "error",
         event: "ai_slop_failed",
         repository: args.repoFullName,
         pullNumber: args.pr.number,

test/unit/queue-console-error-level.test.ts

@@ -0,0 +1,65 @@
+import { readFileSync } from "node:fs";
+import { join } from "node:path";
+import { describe, expect, it } from "vitest";
+
+// #7806 — console.error sinks must not stamp level:"warn" (Sentry severity follows the explicit
+// level field over the sink default). Keep the three queue files consistent with the rest of
+// their console.error call sites.
+const QUEUE_FILES = [
+  "src/queue/processors.ts",
+  "src/queue/slop-detection.ts",
+  "src/queue/ai-review-orchestration.ts",
+] as const;
+
+function consoleErrorBlocks(source: string): string[] {
+  const blocks: string[] = [];
+  let i = 0;
+  while (true) {
+    const start = source.indexOf("console.error(", i);
+    if (start < 0) break;
+    let k = start + "console.error(".length;
+    let depth = 1;
+    while (k < source.length && depth > 0) {
+      const ch = source[k]!;
+      if (ch === "(") depth += 1;
+      else if (ch === ")") depth -= 1;
+      else if (ch === '"' || ch === "'" || ch === "`") {
+        const quote = ch;
+        k += 1;
+        while (k < source.length) {
+          if (source[k] === "\\") {
+            k += 2;
+            continue;
+          }
+          if (source[k] === quote) break;
+          k += 1;
+        }
+      }
+      k += 1;
+    }
+    blocks.push(source.slice(start, k));
+    i = k;
+  }
+  return blocks;
+}
+
+describe("queue console.error level matches the error sink (#7806)", () => {
+  it("never stamps level:\"warn\" inside console.error payloads in the queue pipeline", () => {
+    const mismatches: string[] = [];
+    for (const rel of QUEUE_FILES) {
+      const source = readFileSync(join(process.cwd(), rel), "utf8");
+      for (const block of consoleErrorBlocks(source)) {
+        if (block.includes('level: "warn"') || block.includes("level: 'warn'")) {
+          mismatches.push(rel);
+        }
+      }
+    }
+    expect(mismatches).toEqual([]);
+  });
+
+  it("keeps at least one representative console.error payload at level:\"error\"", () => {
+    const source = readFileSync(join(process.cwd(), "src/queue/slop-detection.ts"), "utf8");
+    expect(source).toMatch(/console\.error\(\s*JSON\.stringify\(\s*\{\s*level:\s*"error"/);
+    expect(source).toContain('event: "ai_slop_failed"');
+  });
+});