[CI] Fail subprocess tests with root-cause error (#23795)

Signed-off-by: Nick Hill <nhill@redhat.com>

requirements/test.in

@@ -21,6 +21,7 @@ ray[cgraph,default]>=2.48.0 # Ray Compiled Graph, required by pipeline paralleli
 sentence-transformers # required for embedding tests
 soundfile # required for audio tests
 jiwer # required for audio tests
+tblib # for pickling test exceptions
 timm >=1.0.17 # required for internvl and gemma3n-mm test
 torch==2.8.0
 torchaudio==2.8.0

requirements/test.txt

@@ -137,7 +137,7 @@ contourpy==1.3.0
     # via matplotlib
 cramjam==2.9.0
     # via fastparquet
-cupy-cuda12x==13.3.0
+cupy-cuda12x==13.6.0
     # via ray
 cycler==0.12.1
     # via matplotlib
@@ -1032,6 +1032,8 @@ tabledata==1.3.3
     # via pytablewriter
 tabulate==0.9.0
     # via sacrebleu
+tblib==3.1.0
+    # via -r requirements/test.in
 tcolorpy==0.1.6
     # via pytablewriter
 tenacity==9.0.0

tests/async_engine/test_api_server.py

@@ -1,6 +1,7 @@
 # SPDX-License-Identifier: Apache-2.0
 # SPDX-FileCopyrightText: Copyright contributors to the vLLM project
 
+import copyreg
 import os
 import subprocess
 import sys
@@ -10,6 +11,30 @@ from pathlib import Path
 
 import pytest
 import requests
+import urllib3.exceptions
+
+
+def _pickle_new_connection_error(obj):
+    """Custom pickler for NewConnectionError to fix tblib compatibility."""
+    # Extract the original message by removing the "conn: " prefix
+    full_message = obj.args[0] if obj.args else ""
+    if ': ' in full_message:
+        # Split off the connection part and keep the actual message
+        _, actual_message = full_message.split(': ', 1)
+    else:
+        actual_message = full_message
+    return _unpickle_new_connection_error, (actual_message, )
+
+
+def _unpickle_new_connection_error(message):
+    """Custom unpickler for NewConnectionError."""
+    # Create with None as conn and the actual message
+    return urllib3.exceptions.NewConnectionError(None, message)
+
+
+# Register the custom pickle/unpickle functions for tblib compatibility
+copyreg.pickle(urllib3.exceptions.NewConnectionError,
+               _pickle_new_connection_error)
 
 
 def _query_server(prompt: str, max_tokens: int = 5) -> dict:
@@ -52,6 +77,7 @@ def api_server(distributed_executor_backend: str):
     uvicorn_process.terminate()
 
 
+@pytest.mark.timeout(300)
 @pytest.mark.parametrize("distributed_executor_backend", ["mp", "ray"])
 def test_api_server(api_server, distributed_executor_backend: str):
     """

tests/conftest.py

@@ -1,5 +1,15 @@
 # SPDX-License-Identifier: Apache-2.0
 # SPDX-FileCopyrightText: Copyright contributors to the vLLM project
+
+# ruff: noqa
+
+from tblib import pickling_support
+
+# Install support for pickling exceptions so that we can nicely propagate
+# failures from tests running in a subprocess.
+# This should be run before any custom exception subclasses are defined.
+pickling_support.install()
+
 import http.server
 import json
 import math

tests/utils.py

@@ -2,6 +2,7 @@
 # SPDX-FileCopyrightText: Copyright contributors to the vLLM project
 
 import asyncio
+import contextlib
 import copy
 import functools
 import importlib
@@ -13,7 +14,7 @@ import sys
 import tempfile
 import time
 import warnings
-from contextlib import contextmanager, suppress
+from contextlib import ExitStack, contextmanager, suppress
 from multiprocessing import Process
 from pathlib import Path
 from typing import Any, Callable, Literal, Optional, Union
@@ -800,43 +801,106 @@ _P = ParamSpec("_P")
 
 
 def fork_new_process_for_each_test(
-        f: Callable[_P, None]) -> Callable[_P, None]:
+        func: Callable[_P, None]) -> Callable[_P, None]:
     """Decorator to fork a new process for each test function.
     See https://github.com/vllm-project/vllm/issues/7053 for more details.
     """
 
-    @functools.wraps(f)
+    @functools.wraps(func)
     def wrapper(*args: _P.args, **kwargs: _P.kwargs) -> None:
         # Make the process the leader of its own process group
         # to avoid sending SIGTERM to the parent process
         os.setpgrp()
         from _pytest.outcomes import Skipped
-        pid = os.fork()
-        print(f"Fork a new process to run a test {pid}")
-        if pid == 0:
-            try:
-                f(*args, **kwargs)
-            except Skipped as e:
-                # convert Skipped to exit code 0
-                print(str(e))
-                os._exit(0)
-            except Exception:
-                import traceback
-                traceback.print_exc()
-                os._exit(1)
+
+        # Create a unique temporary file to store exception info from child
+        # process. Use test function name and process ID to avoid collisions.
+        with tempfile.NamedTemporaryFile(
+                delete=False,
+                mode='w+b',
+                prefix=f"vllm_test_{func.__name__}_{os.getpid()}_",
+                suffix=".exc") as exc_file, ExitStack() as delete_after:
+            exc_file_path = exc_file.name
+            delete_after.callback(os.remove, exc_file_path)
+
+            pid = os.fork()
+            print(f"Fork a new process to run a test {pid}")
+            if pid == 0:
+                # Parent process responsible for deleting, don't delete
+                # in child.
+                delete_after.pop_all()
+                try:
+                    func(*args, **kwargs)
+                except Skipped as e:
+                    # convert Skipped to exit code 0
+                    print(str(e))
+                    os._exit(0)
+                except Exception as e:
+                    import traceback
+                    tb_string = traceback.format_exc()
+
+                    # Try to serialize the exception object first
+                    exc_to_serialize: dict[str, Any]
+                    try:
+                        # First, try to pickle the actual exception with
+                        # its traceback.
+                        exc_to_serialize = {'pickled_exception': e}
+                        # Test if it can be pickled
+                        cloudpickle.dumps(exc_to_serialize)
+                    except (Exception, KeyboardInterrupt):
+                        # Fall back to string-based approach.
+                        exc_to_serialize = {
+                            'exception_type': type(e).__name__,
+                            'exception_msg': str(e),
+                            'traceback': tb_string,
+                        }
+                    try:
+                        with open(exc_file_path, 'wb') as f:
+                            cloudpickle.dump(exc_to_serialize, f)
+                    except Exception:
+                        # Fallback: just print the traceback.
+                        print(tb_string)
+                    os._exit(1)
+                else:
+                    os._exit(0)
             else:
-                os._exit(0)
-        else:
-            pgid = os.getpgid(pid)
-            _pid, _exitcode = os.waitpid(pid, 0)
-            # ignore SIGTERM signal itself
-            old_signal_handler = signal.signal(signal.SIGTERM, signal.SIG_IGN)
-            # kill all child processes
-            os.killpg(pgid, signal.SIGTERM)
-            # restore the signal handler
-            signal.signal(signal.SIGTERM, old_signal_handler)
-            assert _exitcode == 0, (f"function {f} failed when called with"
-                                    f" args {args} and kwargs {kwargs}")
+                pgid = os.getpgid(pid)
+                _pid, _exitcode = os.waitpid(pid, 0)
+                # ignore SIGTERM signal itself
+                old_signal_handler = signal.signal(signal.SIGTERM,
+                                                   signal.SIG_IGN)
+                # kill all child processes
+                os.killpg(pgid, signal.SIGTERM)
+                # restore the signal handler
+                signal.signal(signal.SIGTERM, old_signal_handler)
+                if _exitcode != 0:
+                    # Try to read the exception from the child process
+                    exc_info = {}
+                    if os.path.exists(exc_file_path):
+                        with contextlib.suppress(Exception), \
+                            open(exc_file_path, 'rb') as f:
+                            exc_info = cloudpickle.load(f)
+
+                    if (original_exception :=
+                            exc_info.get('pickled_exception')) is not None:
+                        # Re-raise the actual exception object if it was
+                        # successfully pickled.
+                        assert isinstance(original_exception, Exception)
+                        raise original_exception
+
+                    if (original_tb := exc_info.get("traceback")) is not None:
+                        # Use string-based traceback for fallback case
+                        raise AssertionError(
+                            f"Test {func.__name__} failed when called with"
+                            f" args {args} and kwargs {kwargs}"
+                            f" (exit code: {_exitcode}):\n{original_tb}"
+                        ) from None
+
+                    # Fallback to the original generic error
+                    raise AssertionError(
+                        f"function {func.__name__} failed when called with"
+                        f" args {args} and kwargs {kwargs}"
+                        f" (exit code: {_exitcode})") from None
 
     return wrapper
 

vllm/executor/ray_distributed_executor.py

@@ -117,10 +117,12 @@ class RayDistributedExecutor(DistributedExecutorBase):
                 self.driver_worker.execute_method)
 
     def shutdown(self) -> None:
-        logger.info(
-            "Shutting down Ray distributed executor. If you see error log "
-            "from logging.cc regarding SIGTERM received, please ignore because "
-            "this is the expected termination process in Ray.")
+        if logger:
+            # Somehow logger can be None here.
+            logger.info(
+                "Shutting down Ray distributed executor. If you see error log "
+                "from logging.cc regarding SIGTERM received, please ignore "
+                "because this is the expected termination process in Ray.")
         if hasattr(self, "forward_dag") and self.forward_dag is not None:
             self.forward_dag.teardown()
             import ray