fix(tui): add area offset to settings popup positioning (closes #31)

- Report save failures in settings instead of silently discarding errors
- Save draft first, commit color_config only on success (prevents split-brain)
- Show error message in red on status bar, stay in Settings mode on failure
- Clear error on Esc, entering settings, or any settings edit
- Rewrite truncate_to_columns as dedicated O(prefix) truncator
- Tab: stop before tab if expansion would exceed width
- Fixes pre-existing test_truncate_to_columns_tab failure

Cargo.lock

@@ -2358,6 +2358,7 @@ dependencies = [
  "ratatui",
  "serde_json",
  "tempfile",
+ "unicode-width",
 ]
 
 [[package]]

crates/core/src/io/progressive_reader.rs

@@ -223,6 +223,9 @@ pub fn compute_line_visual_height(
     }
     if json_format {
         let formatted = format_json_line(line_text);
+        if formatted.len() > MAX_WRAP_INPUT_LEN {
+            return 1;
+        }
         compute_text_visual_height(&formatted, terminal_width)
     } else {
         compute_text_visual_height(line_text, terminal_width)

crates/core/src/io/wrap.rs

@@ -1,10 +1,16 @@
 /// Maximum input length for wrap/format operations (10 MB).
-/// Lines exceeding this are returned as-is to avoid pathological cases.
+/// Callers should check against this constant before invoking `wrap_line_chars`
+/// to avoid pathological cases on oversized lines.
 pub const MAX_WRAP_INPUT_LEN: usize = 10 * 1024 * 1024;
 
+/// Column spacing for tab stop alignment.
+const TAB_WIDTH: usize = 4;
+
 /// Split a line into chunks of exactly `width` display columns.
 /// For a log viewer, we want character-level wrapping, not word-level.
 /// Uses `unicode-width` for correct CJK/emoji/zero-width handling.
+/// Tab characters expand to the next tab-stop boundary and split across
+/// rows when the expansion exceeds the remaining width.
 pub fn wrap_line_chars(line: &str, width: usize) -> Vec<String> {
     use unicode_width::UnicodeWidthChar;
 
@@ -18,9 +24,24 @@ pub fn wrap_line_chars(line: &str, width: usize) -> Vec<String> {
     let mut row = String::new();
     let mut col = 0;
     for ch in line.chars() {
-        let w = if ch == '\t' {
-            4
-        } else if ch.is_control() {
+        if ch == '\t' {
+            let tab_stop = TAB_WIDTH - (col % TAB_WIDTH);
+            let mut remaining = tab_stop;
+            while remaining > 0 {
+                let avail = width.saturating_sub(col);
+                let fill = remaining.min(avail);
+                for _ in 0..fill {
+                    row.push(' ');
+                }
+                col += fill;
+                remaining -= fill;
+                if col >= width {
+                    result.push(std::mem::take(&mut row));
+                    col = 0;
+                }
+            }
+        } else {
+            let w = if ch.is_control() {
                 // Control characters (except tab): width 0, still pushed to preserve content.
                 // Visible rendering is the caller's responsibility.
                 0
@@ -31,18 +52,14 @@ pub fn wrap_line_chars(line: &str, width: usize) -> Vec<String> {
                 result.push(std::mem::take(&mut row));
                 col = 0;
             }
-        if ch == '\t' {
-            row.push_str("    ");
-            col += 4;
-        } else {
             row.push(ch);
             col += w;
-        }
             if col >= width {
                 result.push(std::mem::take(&mut row));
                 col = 0;
             }
         }
+    }
     if !row.is_empty() {
         result.push(row);
     }
@@ -107,7 +124,7 @@ mod tests {
     #[test]
     fn test_wrap_with_tab() {
         let result = wrap_line_chars("a\tb", 4);
-        assert_eq!(result, vec!["a", "    ", "b"]);
+        assert_eq!(result, vec!["a   ", "b"]);
     }
 
     #[test]
@@ -187,4 +204,31 @@ mod tests {
         let result = wrap_line_chars("你好", 1);
         assert_eq!(result, vec!["你", "好"]);
     }
+
+    #[test]
+    fn test_tab_narrow_width() {
+        let result = wrap_line_chars("\t", 2);
+        assert_eq!(result, vec!["  ", "  "]);
+        let result = wrap_line_chars("\t", 1);
+        assert_eq!(result, vec![" ", " ", " ", " "]);
+    }
+
+    #[test]
+    fn test_tab_stop_alignment() {
+        assert_eq!(wrap_line_chars("a\tb", 8), vec!["a   b"]);
+        assert_eq!(wrap_line_chars("ab\t", 4), vec!["ab  "]);
+        assert_eq!(wrap_line_chars("abc\tb", 8), vec!["abc b"]);
+    }
+
+    #[test]
+    fn test_tab_at_line_boundary() {
+        let result = wrap_line_chars("a\tb", 4);
+        assert_eq!(result, vec!["a   ", "b"]);
+    }
+
+    #[test]
+    fn test_tab_regression_ab_tab() {
+        let result = wrap_line_chars("ab\t", 4);
+        assert_eq!(result, vec!["ab  "]);
+    }
 }

crates/core/src/parser/level.rs

@@ -100,13 +100,21 @@ fn detect_level_from_text(line: &str) -> Option<LogLevel> {
     )
 }
 
+// ─── is_ident_char ─────────────────────────────────────────────────────────
+/// Whether a byte looks like an ASCII identifier continuation character
+/// (letter / digit / underscore). Log-level keywords must NOT be adjacent to
+/// such characters to count as a valid word boundary.
+fn is_ident_char(b: u8) -> bool {
+    b.is_ascii_alphanumeric() || b == b'_'
+}
+
 // ─── is_word_boundary ───────────────────────────────────────────────────────
-/// Check that the match at `start..start+len` is surrounded by non-alphabetic
+/// Check that the match at `start..start+len` is surrounded by non-identifier
 /// characters (or the string edge).
 fn is_word_boundary(text: &str, start: usize, len: usize) -> bool {
-    let before_ok = start == 0 || !text.as_bytes()[start - 1].is_ascii_alphabetic();
+    let before_ok = start == 0 || !is_ident_char(text.as_bytes()[start - 1]);
     let after_idx = start + len;
-    let after_ok = after_idx >= text.len() || !text.as_bytes()[after_idx].is_ascii_alphabetic();
+    let after_ok = after_idx >= text.len() || !is_ident_char(text.as_bytes()[after_idx]);
     before_ok && after_ok
 }
 
@@ -209,4 +217,36 @@ mod tests {
         let line = format!("{prefix} ERROR something");
         assert_eq!(detect_level(&line), Some(LogLevel::Error));
     }
+
+    #[test]
+    fn test_boundary_rejects_trailing_digits() {
+        assert_eq!(detect_level("ERROR123"), None);
+        assert_eq!(detect_level("WARN2: bad"), None);
+        assert_eq!(detect_level("ERR2"), None);
+    }
+
+    #[test]
+    fn test_boundary_rejects_underscore() {
+        assert_eq!(detect_level("INFO_foo"), None);
+        assert_eq!(detect_level("DBG_value=5"), None);
+    }
+
+    #[test]
+    fn test_boundary_rejects_leading_digits_and_underscore() {
+        assert_eq!(detect_level("123ERROR: fail"), None);
+        assert_eq!(detect_level("foo_ERROR: fail"), None);
+        assert_eq!(detect_level("1WRN"), None);
+    }
+
+    #[test]
+    fn test_boundary_accepts_valid_suffixes() {
+        assert_eq!(detect_level("ERROR: fail"), Some(LogLevel::Error));
+        assert_eq!(detect_level("[ERROR] fail"), Some(LogLevel::Error));
+        assert_eq!(detect_level("ERROR fail"), Some(LogLevel::Error));
+    }
+
+    #[test]
+    fn test_boundary_camel_case_regression() {
+        assert_eq!(detect_level("errorLevel"), None);
+    }
 }

crates/tui/Cargo.toml

@@ -11,6 +11,7 @@ anyhow.workspace = true
 log-viewer-core.workspace = true
 serde_json.workspace = true
 crossbeam-channel.workspace = true
+unicode-width.workspace = true
 
 [dev-dependencies]
 tempfile = { workspace = true }

crates/tui/src/ui.rs

@@ -88,9 +88,21 @@ pub fn render(frame: &mut ratatui::Frame, app: &mut App) {
     }
 
     // ── Status bar ─────────────────────────────────────────────────
-    let status_text = if app.mode == AppMode::Settings {
-        " j/k:navigate  ←/→:change  1-8:jump  Enter:save  Esc:cancel"
-    } else if app.is_error() {
+    if app.mode == AppMode::Settings {
+        if let Some(ref err) = app.settings_error {
+            frame.render_widget(
+                Paragraph::new(err.as_str()).style(Style::default().fg(Color::Red)),
+                outer[2],
+            );
+        } else {
+            frame.render_widget(
+                Paragraph::new(" j/k:navigate  ←/→:change  1-8:jump  Enter:save  Esc:cancel"),
+                outer[2],
+            );
+        }
+        return;
+    }
+    let status_text = if app.is_error() {
         " Press q to quit"
     } else if app.is_loading() {
         let pct = app.loading_progress().map_or(0, |p| p as usize);
@@ -130,8 +142,8 @@ pub fn render_settings(frame: &mut ratatui::Frame, app: &mut App, area: ratatui:
 
     let popup_w = ((area.width as u32 * 4 / 5).max(40)).min(area.width as u32) as u16;
     let popup_h = ((area.height as u32 * 4 / 5).max(14)).min(area.height as u32) as u16;
-    let popup_x = area.width.saturating_sub(popup_w) / 2;
-    let popup_y = area.height.saturating_sub(popup_h) / 2;
+    let popup_x = area.x.saturating_add(area.width.saturating_sub(popup_w) / 2);
+    let popup_y = area.y.saturating_add(area.height.saturating_sub(popup_h) / 2);
     let popup = ratatui::layout::Rect::new(popup_x, popup_y, popup_w, popup_h);
 
     let block = Block::new().borders(Borders::ALL).title(" Color Settings ");
@@ -493,4 +505,74 @@ mod tests {
         let _ = std::fs::remove_file(&path);
         assert!(result.is_ok());
     }
+
+    // ── Issue #31: Settings popup area offset tests ────────────────
+
+    /// Helper: enter settings mode and render to buffer.
+    fn render_settings_to_buffer(app: &mut App, width: u16, height: u16) -> ratatui::buffer::Buffer {
+        app.mode = crate::app::AppMode::Settings;
+        app.settings_draft = app.color_config.clone();
+        render_to_buffer(app, width, height)
+    }
+
+    /// Find the top-left corner of the popup border by scanning for '┌'.
+    fn find_popup_top_left(buf: &ratatui::buffer::Buffer, width: u16, height: u16) -> Option<(u16, u16)> {
+        for row in 0..height {
+            for col in 0..width {
+                if buf.cell((col, row)).unwrap().symbol() == "┌" {
+                    return Some((col, row));
+                }
+            }
+        }
+        None
+    }
+
+    #[test]
+    fn test_settings_popup_includes_area_offset() {
+        // In an 80x24 frame with Layout [Length(1), Min(1), Length(1)]:
+        //   outer[0] = title bar  -> y=0
+        //   outer[1] = content    -> y=1, height=22
+        //   outer[2] = status bar -> y=23
+        // The popup is centered within outer[1], so its y must be >= outer[1].y (which is 1).
+        let mut app = App::new();
+        let buf = render_settings_to_buffer(&mut app, 80, 24);
+
+        let (_px, py) = find_popup_top_left(&buf, 80, 24)
+            .expect("popup border '┌' should be rendered");
+
+        // outer[1].y == 1; the popup is centered inside a 22-row area,
+        // so popup_y must be at least 1 (not 0).
+        assert!(
+            py >= 1,
+            "popup top row should account for area.y offset, got y={py} (expected >= 1)"
+        );
+    }
+
+    #[test]
+    fn test_settings_popup_horizontal_centering_uses_area_x() {
+        // outer[1].x is 0 for this layout, so this mainly verifies the popup
+        // is centered and not shifted left. A non-zero area.x layout would
+        // need a different layout to trigger, but the formula is the same.
+        let mut app = App::new();
+        let buf = render_settings_to_buffer(&mut app, 80, 24);
+
+        let (px, _py) = find_popup_top_left(&buf, 80, 24)
+            .expect("popup border '┌' should be rendered");
+
+        // popup_w = 80*4/5 = 64, centered: (80-64)/2 = 8
+        assert_eq!(
+            px, 8,
+            "popup should start at x=8 (centered 64-wide popup in 80-col area)"
+        );
+    }
+
+    #[test]
+    fn test_settings_popup_small_frame_no_panic() {
+        // Frame smaller than the min popup size (40x14) should not panic.
+        let result = std::panic::catch_unwind(std::panic::AssertUnwindSafe(|| {
+            let mut app = App::new();
+            let _buf = render_settings_to_buffer(&mut app, 30, 10);
+        }));
+        assert!(result.is_ok(), "rendering settings in a small frame should not panic");
+    }
 }