feat: Implement comprehensive validation error handling

src/components/moderation/SubmissionReviewManager.tsx

@@ -247,28 +247,68 @@ export function SubmissionReviewManager({
       }
 
       // Run validation on all selected items
-      const validationResultsMap = await validateMultipleItems(
-        selectedItems.map(item => ({
-          item_type: item.item_type,
-          item_data: item.item_data,
-          id: item.id
-        }))
-      );
+      let validationResultsMap: Map<string, any>;
       
-      setValidationResults(validationResultsMap);
-      
-      // Check for blocking errors
-      const itemsWithBlockingErrors = selectedItems.filter(item => {
-        const result = validationResultsMap.get(item.id);
-        return result && result.blockingErrors.length > 0;
-      });
-      
-      // CRITICAL: Blocking errors can NEVER be bypassed, regardless of warnings
-      if (itemsWithBlockingErrors.length > 0) {
-        setHasBlockingErrors(true);
-        setShowValidationBlockerDialog(true);
-        dispatch({ type: 'ERROR', payload: { error: 'Validation failed' } });
-        return; // Block approval
+      try {
+        validationResultsMap = await validateMultipleItems(
+          selectedItems.map(item => ({
+            item_type: item.item_type,
+            item_data: item.item_data,
+            id: item.id
+          }))
+        );
+        
+        setValidationResults(validationResultsMap);
+        
+        // Check for blocking errors
+        const itemsWithBlockingErrors = selectedItems.filter(item => {
+          const result = validationResultsMap.get(item.id);
+          return result && result.blockingErrors.length > 0;
+        });
+        
+        // CRITICAL: Blocking errors can NEVER be bypassed, regardless of warnings
+        if (itemsWithBlockingErrors.length > 0) {
+          // Log which items have blocking errors
+          itemsWithBlockingErrors.forEach(item => {
+            const result = validationResultsMap.get(item.id);
+            logger.error('Blocking validation errors prevent approval', {
+              submissionId,
+              itemId: item.id,
+              itemType: item.item_type,
+              errors: result?.blockingErrors
+            });
+          });
+          
+          setHasBlockingErrors(true);
+          setShowValidationBlockerDialog(true);
+          dispatch({ type: 'ERROR', payload: { error: 'Validation failed' } });
+          return; // Block approval
+        }
+      } catch (error) {
+        // Validation itself failed (network error, bug, etc.)
+        const errorId = handleError(error, {
+          action: 'Validation System Error',
+          userId: user?.id,
+          metadata: {
+            submissionId,
+            selectedItemCount: selectedItems.length,
+            itemTypes: selectedItems.map(i => i.item_type)
+          }
+        });
+        
+        toast({
+          title: 'Validation System Error',
+          description: (
+            <div className="space-y-2">
+              <p>Unable to validate submission. Please try again.</p>
+              <p className="text-xs font-mono">Ref: {errorId.slice(0, 8)}</p>
+            </div>
+          ),
+          variant: 'destructive'
+        });
+        
+        dispatch({ type: 'ERROR', payload: { error: 'Validation system error' } });
+        return;
       }
       
       // Check for warnings

src/components/moderation/ValidationBlockerDialog.tsx

@@ -1,4 +1,5 @@
-import { AlertCircle } from 'lucide-react';
+import { useState } from 'react';
+import { AlertCircle, ChevronDown } from 'lucide-react';
 import {
   AlertDialog,
   AlertDialogAction,
@@ -9,6 +10,9 @@ import {
   AlertDialogTitle,
 } from '@/components/ui/alert-dialog';
 import { Alert, AlertDescription } from '@/components/ui/alert';
+import { Badge } from '@/components/ui/badge';
+import { Button } from '@/components/ui/button';
+import { Collapsible, CollapsibleContent, CollapsibleTrigger } from '@/components/ui/collapsible';
 import { ValidationError } from '@/lib/entityValidationSchemas';
 
 interface ValidationBlockerDialogProps {
@@ -24,9 +28,11 @@ export function ValidationBlockerDialog({
   blockingErrors,
   itemNames,
 }: ValidationBlockerDialogProps) {
+  const [showDetails, setShowDetails] = useState(false);
+  
   return (
     <AlertDialog open={open} onOpenChange={onClose}>
-      <AlertDialogContent>
+      <AlertDialogContent className="max-w-2xl">
         <AlertDialogHeader>
           <AlertDialogTitle className="flex items-center gap-2 text-destructive">
             <AlertCircle className="w-5 h-5" />
@@ -34,28 +40,51 @@ export function ValidationBlockerDialog({
           </AlertDialogTitle>
           <AlertDialogDescription>
             The following items have blocking validation errors that MUST be fixed before approval.
-            These items cannot be approved until the errors are resolved. Please edit or reject them.
+            Edit the items to fix the errors, or reject them.
           </AlertDialogDescription>
         </AlertDialogHeader>
 
         <div className="space-y-3 my-4">
-          {itemNames.map((name, index) => (
-            <div key={index} className="space-y-2">
-              <div className="font-medium text-sm">{name}</div>
-              <Alert variant="destructive">
-                <AlertDescription className="space-y-1">
-                  {blockingErrors
-                    .filter((_, i) => i === index || itemNames.length === 1)
-                    .map((error, errIndex) => (
+          {itemNames.map((name, index) => {
+            const itemErrors = blockingErrors.filter((_, i) => 
+              itemNames.length === 1 || i === index
+            );
+            
+            return (
+              <div key={index} className="space-y-2">
+                <div className="font-medium text-sm flex items-center justify-between">
+                  <span>{name}</span>
+                  <Badge variant="destructive">
+                    {itemErrors.length} error{itemErrors.length > 1 ? 's' : ''}
+                  </Badge>
+                </div>
+                <Alert variant="destructive">
+                  <AlertDescription className="space-y-1">
+                    {itemErrors.map((error, errIndex) => (
                       <div key={errIndex} className="text-sm">
                         • <span className="font-medium">{error.field}:</span> {error.message}
                       </div>
                     ))}
-                </AlertDescription>
-              </Alert>
-            </div>
-          ))}
+                  </AlertDescription>
+                </Alert>
+              </div>
+            );
+          })}
         </div>
+        
+        <Collapsible open={showDetails} onOpenChange={setShowDetails}>
+          <CollapsibleTrigger asChild>
+            <Button variant="ghost" size="sm" className="w-full">
+              {showDetails ? 'Hide' : 'Show'} Technical Details
+              <ChevronDown className={`ml-2 h-4 w-4 transition-transform ${showDetails ? 'rotate-180' : ''}`} />
+            </Button>
+          </CollapsibleTrigger>
+          <CollapsibleContent className="mt-2">
+            <div className="bg-muted p-3 rounded text-xs font-mono max-h-60 overflow-auto">
+              <pre>{JSON.stringify(blockingErrors, null, 2)}</pre>
+            </div>
+          </CollapsibleContent>
+        </Collapsible>
 
         <AlertDialogFooter>
           <AlertDialogAction onClick={onClose}>

src/hooks/moderation/useModerationActions.ts

@@ -171,42 +171,93 @@ export function useModerationActions(config: ModerationActionsConfig): Moderatio
               });
               
               // Run validation on all items
-              const validationResults = await validateMultipleItems(itemsWithData);
-              
-              // Check for blocking errors
-              const itemsWithBlockingErrors = itemsWithData.filter(item => {
-                const result = validationResults.get(item.id);
-                return result && result.blockingErrors.length > 0;
-              });
-              
-              // CRITICAL: Block approval if any item has blocking errors
-              if (itemsWithBlockingErrors.length > 0) {
-                const errorDetails = itemsWithBlockingErrors.map(item => {
+              try {
+                const validationResults = await validateMultipleItems(itemsWithData);
+                
+                // Check for blocking errors
+                const itemsWithBlockingErrors = itemsWithData.filter(item => {
                   const result = validationResults.get(item.id);
-                  return `${item.item_type}: ${result?.blockingErrors[0]?.message || 'Unknown error'}`;
-                }).join(', ');
-                
-                toast({
-                  title: 'Cannot Approve - Validation Errors',
-                  description: `${itemsWithBlockingErrors.length} item(s) have blocking errors that must be fixed first. ${errorDetails}`,
-                  variant: 'destructive',
+                  return result && result.blockingErrors.length > 0;
                 });
                 
-                // Return early - do NOT proceed with approval
-                return;
-              }
-              
-              // Check for warnings (optional - can proceed but inform user)
-              const itemsWithWarnings = itemsWithData.filter(item => {
-                const result = validationResults.get(item.id);
-                return result && result.warnings.length > 0;
-              });
-              
-              if (itemsWithWarnings.length > 0) {
-                logger.info('Approval proceeding with warnings', {
-                  submissionId: item.id,
-                  warningCount: itemsWithWarnings.length
+                // CRITICAL: Block approval if any item has blocking errors
+                if (itemsWithBlockingErrors.length > 0) {
+                  // Log detailed blocking errors
+                  itemsWithBlockingErrors.forEach(item => {
+                    const result = validationResults.get(item.id);
+                    logger.error('Validation blocking approval', {
+                      submissionId: item.id,
+                      itemId: item.id,
+                      itemType: item.item_type,
+                      blockingErrors: result?.blockingErrors
+                    });
+                  });
+                  
+                  const errorDetails = itemsWithBlockingErrors.map(item => {
+                    const result = validationResults.get(item.id);
+                    const itemName = (item.item_data as any)?.name || item.item_type;
+                    const errors = result?.blockingErrors.map(e => `${e.field}: ${e.message}`).join(', ');
+                    return `${itemName} - ${errors}`;
+                  }).join('; ');
+                  
+                  throw new Error(`Validation failed: ${errorDetails}`);
+                }
+                
+                // Check for warnings (optional - can proceed but inform user)
+                const itemsWithWarnings = itemsWithData.filter(item => {
+                  const result = validationResults.get(item.id);
+                  return result && result.warnings.length > 0;
                 });
+                
+                if (itemsWithWarnings.length > 0) {
+                  logger.info('Approval proceeding with warnings', {
+                    submissionId: item.id,
+                    warningCount: itemsWithWarnings.length
+                  });
+                }
+              } catch (error) {
+                // Check if this is a validation error or system error
+                if (getErrorMessage(error).includes('Validation failed:')) {
+                  // This is expected - validation rules preventing approval
+                  handleError(error, {
+                    action: 'Validation Blocked Approval',
+                    userId: user?.id,
+                    metadata: {
+                      submissionId: item.id,
+                      submissionType: item.submission_type,
+                      selectedItemCount: itemsWithData.length
+                    }
+                  });
+                  
+                  toast({
+                    title: 'Cannot Approve - Validation Errors',
+                    description: getErrorMessage(error),
+                    variant: 'destructive',
+                  });
+                  
+                  // Return early - do NOT proceed with approval
+                  return;
+                } else {
+                  // Unexpected validation system error
+                  const errorId = handleError(error, {
+                    action: 'Validation System Failure',
+                    userId: user?.id,
+                    metadata: {
+                      submissionId: item.id,
+                      submissionType: item.submission_type,
+                      phase: 'validation'
+                    }
+                  });
+                  
+                  toast({
+                    title: 'Validation System Error',
+                    description: `Unable to validate submission (ref: ${errorId.slice(0, 8)})`,
+                    variant: 'destructive',
+                  });
+                  
+                  // Return early - do NOT proceed with approval
+                  return;
+                }
               }
             }
 

src/lib/entityValidationSchemas.ts

@@ -1,5 +1,7 @@
 import { z } from 'zod';
 import { supabase } from '@/lib/supabaseClient';
+import { handleNonCriticalError, getErrorMessage } from '@/lib/errorHandler';
+import { logger } from '@/lib/logger';
 
 // ============================================
 // CENTRALIZED VALIDATION SCHEMAS
@@ -452,35 +454,71 @@ export async function validateEntityData(
   entityType: keyof typeof entitySchemas,
   data: unknown
 ): Promise<ValidationResult> {
-  const schema = entitySchemas[entityType];
-  
-  if (!schema) {
-    return {
-      isValid: false,
-      blockingErrors: [{ field: 'entity_type', message: `Unknown entity type: ${entityType}`, severity: 'blocking' }],
-      warnings: [],
-      suggestions: [],
-      allErrors: [{ field: 'entity_type', message: `Unknown entity type: ${entityType}`, severity: 'blocking' }],
-    };
-  }
-
-  const result = schema.safeParse(data);
-  const blockingErrors: ValidationError[] = [];
-  const warnings: ValidationError[] = [];
-  const suggestions: ValidationError[] = [];
-
-  // Process Zod errors
-  if (!result.success) {
-    const zodError = result.error as z.ZodError;
-    zodError.issues.forEach((issue) => {
-      const field = issue.path.join('.');
-      blockingErrors.push({
-        field: field || 'unknown',
-        message: issue.message,
-        severity: 'blocking',
+  try {
+    // Debug logging for operator entity
+    if (entityType === 'operator') {
+      logger.log('Validating operator entity', {
+        dataKeys: data ? Object.keys(data as object) : [],
+        dataTypes: data ? Object.entries(data as object).reduce((acc, [key, val]) => {
+          acc[key] = typeof val;
+          return acc;
+        }, {} as Record<string, string>) : {},
+        rawData: JSON.stringify(data).substring(0, 500)
       });
-    });
-  }
+    }
+
+    const schema = entitySchemas[entityType];
+    
+    if (!schema) {
+      const error = {
+        field: 'entity_type',
+        message: `Unknown entity type: ${entityType}`,
+        severity: 'blocking' as const
+      };
+      
+      handleNonCriticalError(new Error(`Unknown entity type: ${entityType}`), {
+        action: 'Entity Validation',
+        metadata: { entityType, providedData: data }
+      });
+      
+      return {
+        isValid: false,
+        blockingErrors: [error],
+        warnings: [],
+        suggestions: [],
+        allErrors: [error],
+      };
+    }
+
+    const result = schema.safeParse(data);
+    const blockingErrors: ValidationError[] = [];
+    const warnings: ValidationError[] = [];
+    const suggestions: ValidationError[] = [];
+
+    // Process Zod errors
+    if (!result.success) {
+      const zodError = result.error as z.ZodError;
+      
+      // Log detailed validation failure
+      handleNonCriticalError(zodError, {
+        action: 'Zod Validation Failed',
+        metadata: {
+          entityType,
+          issues: zodError.issues,
+          providedData: JSON.stringify(data).substring(0, 500),
+          issueCount: zodError.issues.length
+        }
+      });
+      
+      zodError.issues.forEach((issue) => {
+        const field = issue.path.join('.') || entityType;
+        blockingErrors.push({
+          field,
+          message: `${issue.message} (code: ${issue.code})`,
+          severity: 'blocking',
+        });
+      });
+    }
 
   // Add warnings for optional but recommended fields
   const validData = data as Record<string, unknown>;
@@ -585,16 +623,43 @@ export async function validateEntityData(
     }
   }
 
-  const allErrors = [...blockingErrors, ...warnings, ...suggestions];
-  const isValid = blockingErrors.length === 0;
+    const allErrors = [...blockingErrors, ...warnings, ...suggestions];
+    const isValid = blockingErrors.length === 0;
 
-  return {
-    isValid,
-    blockingErrors,
-    warnings,
-    suggestions,
-    allErrors,
-  };
+    return {
+      isValid,
+      blockingErrors,
+      warnings,
+      suggestions,
+      allErrors,
+    };
+  } catch (error) {
+    // Catch any unexpected errors during validation
+    const errorId = handleNonCriticalError(error, {
+      action: 'Entity Validation Unexpected Error',
+      metadata: {
+        entityType,
+        dataType: typeof data,
+        hasData: !!data
+      }
+    });
+    
+    return {
+      isValid: false,
+      blockingErrors: [{
+        field: entityType,
+        message: `Validation error: ${getErrorMessage(error)} (ref: ${errorId.slice(0, 8)})`,
+        severity: 'blocking'
+      }],
+      warnings: [],
+      suggestions: [],
+      allErrors: [{
+        field: entityType,
+        message: `Validation error: ${getErrorMessage(error)} (ref: ${errorId.slice(0, 8)})`,
+        severity: 'blocking'
+      }],
+    };
+  }
 }
 
 /**