After trimming the fat on the code (removing some participants and 
on_error), I got some more interesting information:

===========================

=> == Ruote::ProcessStatus ==                                               
                 
                                                                            
                 
  wfid:           20130124-1835-jenigopo-kizotogu                           
                 
  name:           approval_process                                         
                  
  revision:       0.1                                                       
                 
  last_active:    2013-01-24 18:35:23.505421 UTC                           
                  
  launched_time:  2013-01-24 18:35:14.330578 UTC                           
                  
                                                                            
                 
  expressions: 8                                                           
                  
                                                                            
                 
     0!de7ded37c1855795de5ff56f896b2905!20130124-1835-jenigopo-kizotogu     
                 
       | define                                                             
                 
       | _rev: "2"                                                         
                  
       | {"name"=>"approval_process", "revision"=>"0.1"}                   
                  
       | . child-> 
0_0!c5395919ffdd8f22159727e3bb48b190!20130124-1835-jenigopo-kizotogu      
       `-parent--> nil                                                     
                  
     0_0!c5395919ffdd8f22159727e3bb48b190!20130124-1835-jenigopo-kizotogu   
                 
       | cursor                                                             
                 
       | _rev: "2"                                                         
                  
       | {}                                                                 
                 
       | . child-> 
0_0_0!547f7120e9127f179aeb1c97868495ad!20130124-1835-jenigopo-kizotogu    
       `-parent--> 
0!de7ded37c1855795de5ff56f896b2905!20130124-1835-jenigopo-kizotogu        
     0_0_0!547f7120e9127f179aeb1c97868495ad!20130124-1835-jenigopo-kizotogu 
                 
       | sequence                                                           
                 
       | _rev: "2"                                                         
                  
       | {}                                                                 
                 
       | . child-> 
0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu  
       `-parent--> 
0_0!c5395919ffdd8f22159727e3bb48b190!20130124-1835-jenigopo-kizotogu      
    
 0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu   
             
       | concurrence                                                       
                  
       | _rev: "2"                                                         
                  
       | {"count"=>1}                                                       
                 
       | . child-> 
0_0_0_0_0!3130995817c1113d14abd9796ed39122!20130124-1835-jenigopo-kizotogu
                                                                            
                 
       | . child-> 
0_0_0_0_1!1863ea9f376abbc7e88bb6526d8c6df1!20130124-1835-jenigopo-kizotogu
                                                                            
                 
       | . child-> 
0_0_0_0_2!029450ea4733726c1bb2c022214a18b0!20130124-1835-jenigopo-kizotogu
                                                                            
                 
       | . child-> 
0_0_0_0_3!d1ff5dd3dd812f5cdacbd0069a4ce51f!20130124-1835-jenigopo-kizotogu
                                                                            
                 
       `-parent--> 
0_0_0!547f7120e9127f179aeb1c97868495ad!20130124-1835-jenigopo-kizotogu    
    
 0_0_0_0_0!3130995817c1113d14abd9796ed39122!20130124-1835-jenigopo-kizotogu 
             
       | participant                                                       
                  
       | _rev: "3"                                                         
                  
       | {"approver_id"=>"1", "approval_step_id"=>"1", 
"ref"=>"approval_step"}               
       `-parent--> 
0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu  
    
 0_0_0_0_1!1863ea9f376abbc7e88bb6526d8c6df1!20130124-1835-jenigopo-kizotogu 
             
       | participant                                                       
                  
       | _rev: "3"                                                         
                  
       | {"approver_id"=>"2", "approval_step_id"=>"1", 
"ref"=>"approval_step"}               
       `-parent--> 
0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu  
    
 0_0_0_0_2!029450ea4733726c1bb2c022214a18b0!20130124-1835-jenigopo-kizotogu 
             
       | participant
       | _rev: "3"                                                         
                  
       | {"approver_id"=>"3", "approval_step_id"=>"1", 
"ref"=>"approval_step"}               
       `-parent--> 
0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu  
    
 0_0_0_0_3!d1ff5dd3dd812f5cdacbd0069a4ce51f!20130124-1835-jenigopo-kizotogu 
             
       | participant                                                       
                  
       | _rev: "2"                                                         
                  
       | {"approver_id"=>"4", "approval_step_id"=>"1", 
"ref"=>"approval_step"}               
       `-parent--> 
0_0_0_0!6bce3c26e8468c7a9e2bafcce345a91c!20130124-1835-jenigopo-kizotogu  
                                                                            
                 
  schedules: 0                                                             
                  
  stored workitems: 3                                                       
                 
                                                                            
                 
  initial workitem fields:                                                 
                  
    "approval_id": 23                                                       
                 
                                                                            
                 
  variables:                                                               
                  
    "approval_process": ["0", ["define", {"name"=>"approval_process", 
"revision"=>"0.1"}, [["
cursor", {}, [["sequence", {}, [["concurrence", {"count"=>1}, 
[["approval_step", {"approver_i
d"=>"1", "approval_step_id"=>"1"}, []], ["approval_step", 
{"approver_id"=>"2", "approval_step
_id"=>"1"}, []], ["approval_step", {"approver_id"=>"3", 
"approval_step_id"=>"1"}, []], ["appr
oval_step", {"approver_id"=>"4", "approval_step_id"=>"1"}, []]]], 
["disburse_step", {}, []]]]
]]]]]                                                                       
                 
                                                                            
                 
  all_variables:                                                           
                  
    "0!de7ded37c1855795de5ff56f896b2905!20130124-1835-jenigopo-kizotogu": 
{"approval_process"
=>["0", ["define", {"name"=>"approval_process", "revision"=>"0.1"}, 
[["cursor", {}, [["sequen
ce", {}, [["concurrence", {"count"=>1}, [["approval_step", 
{"approver_id"=>"1", "approval_ste
p_id"=>"1"}, []], ["approval_step", {"approver_id"=>"2", 
"approval_step_id"=>"1"}, []], ["app
roval_step", {"approver_id"=>"3", "approval_step_id"=>"1"}, []], 
["approval_step", {"approver
_id"=>"4", "approval_step_id"=>"1"}, []]]], ["disburse_step", {}, 
[]]]]]]]]]}                
                                                                            
                 
  errors: 1                                                                 
                 
    ***                                                                     
                 
      
0_0_0_0_3!d1ff5dd3dd812f5cdacbd0069a4ce51f!20130124-1835-jenigopo-kizotogu 
:           
    action: dispatch                                                       
                  
    message: #<ActiveRecord::RecordNotFound: Couldn't find User with id=4 
[WHERE "users"."del
eted_at" IS NULL]>                                                         
                  
    trace:                                                                 
                  
      
/app/vendor/bundle/ruby/1.9.1/gems/activerecord-3.2.6/lib/active_record/relation/finder
_methods.rb:341:in `find_one'                                               
                 
      
/app/vendor/bundle/ruby/1.9.1/gems/activerecord-3.2.6/lib/active_record/relation/finder
_methods.rb:312:in `find_with_ids'                                         
                  
      
/app/vendor/bundle/ruby/1.9.1/gems/activerecord-3.2.6/lib/active_record/relation/finder
_methods.rb:107:in `find'                                                   
                 
      
/app/vendor/bundle/ruby/1.9.1/gems/activerecord-3.2.6/lib/active_record/querying.rb:5:i
n `find'                                                                   
                  
      /app/lib/approval_participant.rb:12:in `on_workitem'                 
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
ol.rb:199:in `block in participant_send'                                   
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
ol.rb:195:in `each'                                                         
                 
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
ol.rb:195:in `participant_send'                                             
                 
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
ol.rb:74:in `do_dispatch'                                                   
                 
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
 
ol.rb:60:in `dispatch'                                                     
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/svc/dispatch_po
ol.rb:45:in `handle'                                                       
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/worker.rb:381:i
n `process'                                                                 
                 
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/worker.rb:195:i
n `process_msgs'                                                           
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/worker.rb:243:i
n `step'                                                                   
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/worker.rb:94:in
 `run'                                                                     
                  
      
/app/vendor/bundle/ruby/1.9.1/bundler/gems/ruote-1fd3945d6376/lib/ruote/worker.rb:105:i
n `block in run_in_thread'                                                 
                  
    details:                                                               
                  
    deviations:                                                             
                 
    fields:                                                                 
                 
      "approval_id": 23                                                     
                 
      "params": {"approver_id"=>"4", "approval_step_id"=>"1", 
"ref"=>"approval_step"}        
      "dispatched_at": "2013-01-24 18:35:23.214933 UTC"

===========================

I guess I'm getting the exception in the log since on_error is removed.

Additional notes:

- The User record in question has existed for about a day - I can find it 
via console
- Using Postgres on Heroku
- Exception appears to be referencing slightly older code -- if I alter a 
participant and re-deploy, could the worker still be referencing an older 
version of a participant?

With this new clue, I think it has to be something more straightforward 
(and probably something stupid I'm missing!)

Cheers,

E

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