fix(governance): broken featureFlags imports + 3 silent fail-opens + extras test

src/lib/machineToken.ts

@@ -1,11 +1,22 @@
 import { createHash, createHmac } from "node:crypto";
+import { createLogger } from "@/shared/utils/logger";
+
+const log = createLogger("auth:machine-token");
+let fallbackLogged = false;
 
 let machineIdSync: (original?: boolean) => string;
 try {
   // Use require() to bypass webpack static analysis that breaks the default export
   const mod = require("node-machine-id");
   machineIdSync = mod.machineIdSync || mod.default?.machineIdSync;
-} catch {
+} catch (err) {
+  if (!fallbackLogged) {
+    fallbackLogged = true;
+    log.error(
+      { err },
+      "machineToken: node-machine-id unavailable — HMAC salt falls back to empty string (security-relevant, all tokens become constant-keyed)"
+    );
+  }
   machineIdSync = () => "";
 }
 

src/lib/resilience/anomalyHook.ts

@@ -9,7 +9,7 @@
  *     telemetry failures
  */
 
-import { isFeatureFlagEnabled } from "@/lib/featureFlags";
+import { isFeatureFlagEnabled } from "@/shared/utils/featureFlags";
 import { resolveSelfHealingSettings } from "./selfHealingSettings";
 import { SelfHealingManager } from "./selfHealingManager";
 import { createAnomalyDetector } from "./anomalyDetector";

src/lib/versionManager/processManager.ts

@@ -4,6 +4,9 @@ import fsSync from "fs";
 import path from "path";
 import os from "os";
 import { setToolStatus, getVersionManagerTool } from "@/lib/db/versionManager";
+import { createLogger } from "@/shared/utils/logger";
+
+const log = createLogger("version-manager:process-manager");
 
 const DEFAULT_PORT = 8317;
 const GRACEFUL_TIMEOUT_MS = 5000;
@@ -149,7 +152,11 @@ export async function getProcessInfo(pid: number): Promise<{
       }
     }
     return { pid, alive: true };
-  } catch {
-    return { pid, alive: true };
+  } catch (err) {
+    log.error(
+      { err, pid, platform: process.platform },
+      "processManager.getProcessInfo: failed to read process info"
+    );
+    return { pid, alive: false };
   }
 }

src/server-init.ts

@@ -125,7 +125,7 @@ async function startServer() {
     // first request after restart. Gated on the feature flag so the
     // default-off behaviour is unchanged.
     try {
-      const { isFeatureFlagEnabled } = await import("./lib/featureFlags");
+      const { isFeatureFlagEnabled } = await import("./shared/utils/featureFlags");
       const { getSelfHealingManager } = await import("./lib/resilience/anomalyHook");
       if (isFeatureFlagEnabled("OMNIROUTE_SELF_HEALING_ENABLED")) {
         const mgr = getSelfHealingManager();
@@ -135,7 +135,7 @@ async function startServer() {
         void mgr; // referenced to ensure the singleton is constructed
       }
     } catch (err) {
-      startupLog.warn({ err }, "Self-healing hydration skipped (non-fatal)");
+      startupLog.error({ err }, "Self-healing hydration skipped (non-fatal)");
     }
 
     startupLog.info("Server started with cloud sync initialized");

src/server/ws/liveServer.ts

@@ -17,6 +17,9 @@ import { WebSocketServer, WebSocket } from "ws";
 import { jwtVerify } from "jose";
 import { createServer, type IncomingMessage, type ServerResponse } from "http";
 import { randomUUID } from "crypto";
+import { createLogger } from "@/shared/utils/logger";
+
+const log = createLogger("ws:live-server");
 
 // ── Types ─────────────────────────────────────────────────────────────────
 
@@ -476,7 +479,12 @@ export async function startLiveDashboardServer(
   // does not block the event loop on a cold import — which would starve concurrent
   // WebSocket handshakes (see loadAuthModule). A failed warm is non-fatal: the
   // handler retries the import lazily.
-  await loadAuthModule().catch(() => {});
+  await loadAuthModule().catch((err) =>
+    log.error(
+      { err },
+      "liveServer: failed to warm auth module — clients may experience cold-import latency"
+    )
+  );
 
   wss.on("connection", async (ws, request) => {
     const pendingMessages: string[] = [];

tests/unit/quota/keyvQuotaStoreExtras.test.ts

@@ -0,0 +1,88 @@
+// @vitest-environment node
+import { describe, it, expect, beforeEach, afterEach } from "vitest";
+import {
+  getKeyvQuotaStore,
+  __resetKeyvQuotaStoreForTests,
+} from "../../../src/lib/quota/keyvQuotaStore";
+import type { ProviderPlan, QuotaPool } from "../../../src/lib/quota/dimensions";
+
+/**
+ * Sanity tests for the "extras" surface of KeyvQuotaStore:
+ * recordPlanUsage, upsertProviderPlan, listProviderPlans, setPools, getPool.
+ *
+ * These methods were originally scoped for a KeyvQuotaStoreExtras class per
+ * plans/quota-keystore-type-drift-spec.md §8.2, but were folded directly into
+ * KeyvQuotaStore before the spec landed. We exercise them here against the
+ * in-memory backing to guarantee the surface stays wired correctly.
+ */
+describe("KeyvQuotaStoreExtras", () => {
+  let store: ReturnType<typeof getKeyvQuotaStore>;
+
+  beforeEach(() => {
+    __resetKeyvQuotaStoreForTests();
+    store = getKeyvQuotaStore({ uri: "memory://" });
+  });
+
+  afterEach(async () => {
+    await store.dispose();
+    __resetKeyvQuotaStoreForTests();
+  });
+
+  it("recordPlanUsage returns a PlanPoolUsage shape with totalConsumed and lastUpdatedAt populated", async () => {
+    const rollup = await store.recordPlanUsage(
+      "conn-1",
+      "openai",
+      "pool-1",
+      [{ unit: "tokens", window: "hourly" }],
+      42,
+    );
+    expect(rollup).toBeDefined();
+    expect(rollup.totalConsumed).toBe(42);
+    expect(typeof rollup.lastUpdatedAt).toBe("number");
+    expect(rollup.lastUpdatedAt).toBeGreaterThan(0);
+  });
+
+  it("upsertProviderPlan writes the plan without throwing", async () => {
+    const plan: ProviderPlan = {
+      connectionId: "conn-1",
+      provider: "openai",
+      dimensions: [{ unit: "tokens", window: "hourly", limit: 1000 }],
+      source: "manual",
+    };
+    await expect(store.upsertProviderPlan(plan)).resolves.toBeUndefined();
+  });
+
+  it("listProviderPlans returns [] even after an upsert (independent surface)", async () => {
+    // upsertProviderPlan and listProviderPlans are independent: the in-memory
+    // store does not enumerate provider plans, so the list stays empty.
+    await store.upsertProviderPlan({
+      connectionId: "conn-1",
+      provider: "openai",
+      dimensions: [{ unit: "tokens", window: "hourly", limit: 1000 }],
+      source: "manual",
+    });
+    const plans = await store.listProviderPlans();
+    expect(plans).toEqual([]);
+  });
+
+  it("setPools persists a QuotaPool retrievable via getPool", async () => {
+    const pool: QuotaPool = {
+      id: "pool-1",
+      connectionId: "conn-1",
+      name: "Primary",
+      createdAt: new Date().toISOString(),
+      allocations: [],
+    };
+    await store.setPools([pool]);
+    const retrieved = await store.getPool("pool-1");
+    expect(retrieved).toBeDefined();
+    expect(retrieved?.id).toBe("pool-1");
+    expect(retrieved?.name).toBe("Primary");
+    expect(retrieved?.allocations).toEqual([]);
+  });
+
+  it("getPool returns undefined for an unknown poolId", async () => {
+    const result = await store.getPool("nonexistent-pool");
+    expect(result).toBeUndefined();
+  });
+});