We had a weird problem like this with ns_shares. There was a race in the shared array variable evaluation code that occurred around 1 in 20K requests on a production server.
To track it down, I had to use 2 dedicated dual-cpu servers on a 100Mbit LAN, and used ab on one server to send simultaneous requests to the other. Since you have a specific URL that fails (I didn't), you should be able to get the failure rate fast enough that you can reproduce the problem quickly. In our case, sending 10K requests per second would cause the failure within a few seconds.
The problem is that it seems that *everything* fails.
The thing is I can't reproduce it, even when doing ab on both the same host and another one on a 100MBit LAN. I've hit about 30000k hits and nothing.
I'll try and add some Ns_Log() statements in 'dqe_return' (ns_return clone used by most of my scripts - but some use ns_return, and those also tend to fail) and check what exactly causes the length to be 0 - if it is the Tcl script, the AOLserver itself or some other weirdness.
If the simulation runs w/o exhibiting this, then your problem might be a context issue: the browser type/version, cookies that are sent with the request, etc., though that seems unlikely since the context should be exactly the same in both requests in your example below.
Well, it even happened to me on Mozilla, so that shouldn't be it.
I don't use cookies much, I only send session ID, and not in all the cases that fail.
-- WK
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