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13 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Feature extraction for subtle anomaly detection using semi-supervised learning

The demand for automated and effective monitoring techniques has soared with the increased digitization of industrial monitoring systems. State-of-the-art machine learning methods are effectively detecting abrupt changes in system states. However, these methods lack comparable maturity in detecting subtle changes that may be signs of incipient faults. This manuscript argues that the current anomaly detection methods can be enhanced by exploring weak patterns to enable subtle variation detection. Specifically, the concept of semi-supervised learning is employed, with labels representing knowledge about some anomalous conditions of a system. The basic idea is to extract a candidate set of weak patterns discarded by state-of-the-art baselining algorithms. With few labeled anomalous data, the algorithm selects the weak patterns and allows for their possible fusion using the highest sensitivity to the labeled anomalies. Here, the method’s applicability is demonstrated using a representative pressurized water reactor (PWR) model simulated by Dymola.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Process Anomaly Detection for Sparsely Labeled Events in Nuclear Power Plants

An essential aspect of online monitoring, subtle anomaly detection increases the detection lead time for equipment failure and enables a nuclear power plant (NPP) to mitigate unexpected partial or full outages, resulting in significant cost saving to the plant. Once an anomaly is detected by plant staff, its cause and severity are investigated. Because the vast majority of anomalies require some level of investigation, including some that require time-consuming examination, before they are passed over to the engineering organization for further analysis, plants are often equipped with tools to assist the staff in performing anomaly detection. Those tools operate as a black box and are often based on statistical methods that establish sensor correlations using preconfigured mathematical models and flag correlation deviations as anomalies. Due to the number of anomalies detected at a given NPP on a daily basis, a significant number of flagged anomalies usually await examination for days or weeks. A primary cause of this backlog is that the methods used by the tools generate many false positives. Though this is usually attributed to oversensitive model settings due to very narrow normal operation bands, it can also be associated with the model development being inadequate for the process being monitored, or with missing model inputs that could have explained misclassified positives. The performance of anomaly detection tools impacts their plant acceptance and utilization, especially when the effort to address false positives generated by the tool depletes the value or cost saved by using that tool. Thus, means to advance anomaly detection performance have been investigated by the Department of Energy’s Light Water Reactor Sustainability program. Previous and ongoing efforts have targeted unsupervised machine-learning (ML) methods, which do not require the labeling of any data fed into the ML model. By contrast, in supervised anomaly detection methods, every data point is labeled as either a normal or abnormal process condition, and the model is trained to replicate the classification process. Supervised methods usually outperform unsupervised methods, due to the added value in differentiating normal from anomalous states of the monitored process. An NPP’s corrective action program requires it to track and document, via a dedicated report, the resolution of any issues that occur within the plant. Once created, each report is reviewed by a plant screening committee, and several classifications and decisions are made. Recently, a collaborating NPP developed an artificial intelligence and ML-based classifier to categorize a condition report (CR) into classes that can serve to label the data as normal or anomalous. Applying CRs as labels represents a semi-supervised use case. Semi-supervised ML assumes that labels exist for some data points (i.e., labeled anomalies, in this case) but not for the rest. In this effort, semi-supervised ML methods were used to fuse data from CRs with anomaly detection methods in order to test the hypothesis that partially labeled anomalies would improve the accuracy of the anomaly detection methods. Specifically, two methods were used. The first is the deep Semi-supervised Anomaly Detection (deep SAD) method, which can handle labels ranging from fully unsupervised to fully supervised cases. The second is a newly designed ML method developed specifically for this effort and referred to as the high-order feature (HOF)-based method. To evaluate these two methods in controlled environments, synthetic data generators were developed and used. The first datasets used a spring-mass-damper (SMD) system simulator commonly found in mechanical engineering references. This was used to create two use cases: a one- and a three-mass system. Anomalies were introduced by changing the spring and damper coefficients while the system was actuated by random forces. The second datasets used the commercial Dymola-Modelica software to build a simplified nuclear reactor model. Anomalies were added in the form of corrupted sensor readings and/or control commands. The deep SAD method was tested using the SMD system, while the HOF method was tested using both datasets. Application of the deep SAD semi-supervised ML method demonstrated that labels can generate increased confidence in detecting true anomalies. This helped increase the number of true positives and decrease the number of false negatives—something that would aid in addressing the backlog of possible anomalies. Application of the HOF method demonstrated that labels can aid in down selecting from a candidate set of features to a more optimal subset in order to better differentiate between normal and anomalous conditions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Presentation: Sensor Anomaly Detection for Nuclear Reactor Systems Utilizing Linear Regression and K-Means Unsupervised Machine Learning: An overview of methods and results

This presentation is a culmination of work which has occurred over the course of a 10-week internship. Anomaly detection methods must be both robust enough to detect subtle anomalies yet not so sensitive to report false positives, which would result significant loss of revenue. Methods currently being developed for autonomous systems are often pursuing a Digital Twin method, which will look at the entire system and model it as a whole. This presentation, however, focuses less on direct application to an NPP, rather acting as a proof of concept for the methods developed. For the project, we look to develop methods to analyze steady-state data and report anomalies.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Robust Spectral Anomaly Detection in EELS Spectral Images via 3D Convolutional Variational Autoencoders

Abstract A 3D Convolutional Variational Autoencoder (3D‐CVAE) is introduced for automated anomaly detection in electron energy‐loss spectroscopy spectrum imaging (EELS‐SI) data. This approach leverages the full 3D structure of EELS‐SI data to detect subtle spectral anomalies while preserving both spatial and spectral correlations across the datacube. By employing cross‐entropy loss and training on bulk spectra, the model learns to reconstruct bulk features characteristic of the defect‐free material. In exploring methods for anomaly detection, both the 3D‐CVAE approach and principal component analysis (PCA) are evaluated, testing their performance using FeL‐edge ΔEpeak shifts designed to simulate material defects. These results show that 3D‐CVAE achieves superior anomaly detection and maintains consistent performance across various shift magnitudes. The method demonstrates clear bimodal separation between bulk and anomalous spectra, enabling reliable classification. Further analysis verifies that lower‐dimensional representations are robust to anomalies in the data. While performance advantages over PCA diminish with decreasing anomaly concentration, our method maintains high reconstruction quality even in challenging, noise‐dominated spectral regions. This approach provides a robust framework for unsupervised automated detection of spectral anomalies in EELS‐SI data, particularly valuable for analyzing complex material systems.

Chemistry↗
DOE OSTI2026

Machine Learning-Based Anomaly Detection for PMT Data Quality Monitoring in the SBN and DUNE

Maintaining high-quality detector data is essential for achieving the scientific objectives of the Short-Baseline Neutrino (SBN) Program at Fermilab. Current data quality monitoring (DQM) procedures rely primarily on threshold-based metrics and manual inspection of detector monitoring plots, making the detection of subtle or gradually developing anomalies both time-consuming and dependent on expert interpretation. This project developed and evaluated a machine-learning workflow for automatically identifying anomalous photomultiplier tube (PMT) channels in the Short-Baseline Near Detector (SBND) using optical-hit amplitude data. A Python-based analysis program was developed to process ROOT files, extract statistical features describing individual PMT amplitude distributions, and generate feature vectors for anomaly detection. These features were used to train an Isolation Forest model using data representing normal detector operation. The trained model was subsequently applied to independent detector runs to identify channels exhibiting statistically unusual behavior relative to the learned reference response. To support expert interpretation, the workflow generated complementary diagnostic products, including anomaly score distributions, normalized amplitude comparisons, decision-tree visualizations, and principal component analysis (PCA) projections. This project demonstrated the feasibility of integrating unsupervised machine learning into detector data-quality monitoring and developed a complete workflow for automated PMT performance assessment to aid expert-driven review. Beyond its technical contributions, the VFP appointment fostered a research collaboration between Aurora University and Fermilab and provided direct workforce development benefits by training the visiting faculty member in detector-scale machine-learning methods that are now being incorporated into undergraduate coursework and research. The methodology developed here provides a foundation for future applications to ProtoDUNE and other liquid argon time projection chamber (LArTPC) detectors, contributing to ongoing efforts to improve detector reliability, reduce manual monitoring requirements, and enable scalable data quality monitoring for future large-scale neutrino experiments, including the Deep Underground Neutrino Experiment (DUNE).

Colón Santana, Juan A. [Unlisted, US, IL]↗
DOE OSTI2026

Reliable statistics-based detection and investigation of anomalies in a SMART valve system

Reliable anomaly detection and diagnosis are critical for the safe operation of complex engineered systems. This study presents a unified framework that integrates statistical, model-based, and data-driven techniques for anomaly detection and investigation, demonstrated on SMART valve systems in hybrid energy applications. Four detection methods—mean deviation, seasonal extreme studentized deviate, ARIMA forecasting, and matrix profiling—were implemented and compared. Matrix profiling was particularly effective in revealing subtle deviations and hidden relationships among variables. Anomaly investigation was performed by analyzing variable-level and grouped signal profiles, with system topology incorporated to distinguish primary faults from propagated effects. Grouping signals by type enhanced interpretability, enabling accurate localization of anomalies across multi-dimensional datasets. Experimental results confirmed the framework's capability to consistently detect and isolate anomalies while providing actionable insights into system interdependencies. The proposed methodology offers a robust, interpretable, and scalable solution for condition monitoring, with potential applications in safety-critical domains such as nuclear energy, aerospace, and process industries.

ARIMA models↗
DOE OSTI2025

Machine Learning for Anomaly Detection in Neural Network Security and SRF Cavities

This dissertation explores the development and deployment of machine learning approaches to address critical challenges in anomaly detection across two distinct domains: neural network security in federated learning settings and cavity behavior analysis in particle accelerator operations at Jefferson Lab in Newport News, Virginia. Anomaly detection identifies deviations from expected patterns, safeguarding systems in cybersecurity, industry, and research against malicious activities and failures. This dissertation demonstrates how our machine learning approaches enhance detection accuracy and efficiency in both neural network security and industrial applications. First, we investigate vulnerabilities in deep neural networks deployed in federated learning. Although federated learning preserves user privacy by training models locally, it remains vulnerable to backdoor attacks, in which malicious participants embed hidden triggers that induce targeted misbehavior. We propose a self-supervised contrastive learning framework to detect and mitigate such backdoor attacks. In our experiments, this method achieves higher detection accuracy and lower false positive rates than existing defenses, while operating without access to local model updates or original training data and thus preserving the privacy guarantees of the federated setting. Second, we address the operational reliability of superconducting radio-frequency (SRF) cavities at the Continuous Electron Beam Accelerator Facility (CEBAF). Our research leverages an unsupervised learning approach, combined with Principal Component Analysis (PCA) and k-means clustering, to identify anomalous behaviors in SRF cavities. Our method detects subtle anomalous behavior by analyzing SRF signal data. This knowledge allows for the early detection and resolution of potential faults, significantly improving the efficiency and reliability of operations. Third, we extend these insights to time-series anomaly detection more broadly. We design a contrastive-learning based model tailored to increasingly dynamic environments and academic research. This model improves detection accuracy in settings that require real-time monitoring and predictive maintenance. Our research underscores the broader applicability and impact of advanced machine learning techniques in anomaly detection. By extracting meaningful patterns from complex data, machine learning can significantly enhance security in distributed neural networks and improve the efficiency of particle accelerator operations. This dissertation serves as a stepping stone for future investigations into the vast possibilities of anomaly detection, inspiring further exploration and development of machine learning techniques in this field.

Ferguson, Hal [Old Dominion University]↗
DOE OSTI2024

Detecting Anomalies for Fire Prevention in Distribution Systems: Challenges and Analytical Techniques

Electric utilities in California have historically been linked to up to 10% of wildfires. To mitigate this risk, Southern California Edison has invested significantly in wildfire prevention strategies, including undergrounding cables and enhancing equipment inspections. This article explores a novel approach to fire prevention by detecting anomalies in the distribution system that may indicate potential fire hazards. The focus is on identifying arcing conditions through high-resolution point-on-wave (POW) measurements. Arcing, a precursor to fires, is challenging to detect due to its subtle transients and complex system topology. The article discusses the use of advanced signal processing and machine learning techniques, such as spectral correlation function and discrete wavelet transform, to extract features from POW data and accurately identify arcing events. The study demonstrates a high accuracy rate in detecting arcing, paving the way for improved fire prevention measures in electric distribution systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Automatic Detection of Defects in High-Reliability Components

Disastrous consequences can result from defects in manufactured parts—particularly the high consequence parts developed at Sandia. Identifying flaws in as-built parts can be done with nondestructive means, such as X-ray Computed Tomography (CT). However, due to artifacts and complex imagery, the task of analyzing the CT images falls to humans. Human analysis is inherently unreproducible, unscalable, and can easily miss subtle flaws. We hypothesized that deep learning methods could improve defect identification, increase the number of parts that can effectively be analyzed, and do it in a reproducible manner. We pursued two methods: 1) generating a defect-free version of a scan and looking for differences (PandaNet), and 2) using pre-trained models to develop a statistical model of normality (Feature-based Anomaly Detection System: FADS). Both PandaNet and FADS provide good results, are scalable, and can identify anomalies in imagery. In particular, FADS enables zero-shot (training-free) identification of defects for minimal computational cost and expert time. It significantly outperforms prior approaches in computational cost while achieving comparable results. FADS’ core concept has also shown utility beyond anomaly detection by providing feature extraction for downstream tasks.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Fast and efficient identification of anomalous galaxy spectra with neural density estimation

ABSTRACT Current large-scale astrophysical experiments produce unprecedented amounts of rich and diverse data. This creates a growing need for fast and flexible automated data inspection methods. Deep learning algorithms can capture and pick up subtle variations in rich data sets and are fast to apply once trained. Here, we study the applicability of an unsupervised and probabilistic deep learning framework, the probabilistic auto-encoder, to the detection of peculiar objects in galaxy spectra from the SDSS survey. Different to supervised algorithms, this algorithm is not trained to detect a specific feature or type of anomaly, instead it learns the complex and diverse distribution of galaxy spectra from training data and identifies outliers with respect to the learned distribution. We find that the algorithm assigns consistently lower probabilities (higher anomaly score) to spectra that exhibit unusual features. For example, the majority of outliers among quiescent galaxies are E+A galaxies, whose spectra combine features from old and young stellar population. Other identified outliers include LINERs, supernovae, and overlapping objects. Conditional modelling further allows us to incorporate additional information. Namely, we evaluate the probability of an object being anomalous given a certain spectral class, but other information such as metrics of data quality or estimated redshift could be incorporated as well. We make our code publicly available.

Böhm, Vanessa↗
DOE OSTI2024

Results from an Aeromagnetic Survey to Detect Steel-Cased Wells at a Marcellus Shale Well Site in Washington County, Pennsylvania

Pennsylvania has a 150-year history of oil and gas production—the longest of any state—and this enduring activity has resulted in the drilling of more than 300,000 recorded wells. However, unknown wells likely exist because innumerable wells were drilled during Pennsylvania’s intense early oil and gas history when incomplete records were kept of well locations. There is concern that early wells are likely to be ineffectively sealed because there were no laws that required plugging when the wells were abandoned. Today, many undocumented and unplugged wells are thought to be in areas of emerging shale gas and shale oil development where open wellbores can provide a pathway for undesired upward migration of fluids and gas from hydraulically fractured reservoirs. Due to this concern, Pennsylvania regulators have asked operators to locate orphaned and abandoned wells within a 1,000-ft buffer of proposed new wells. The objective of this report is to demonstrate that high-resolution aeromagnetic surveys, historic air photos, and Light Detection and Ranging (LiDAR) imagery can be rapid and effective methods to reconnoiter large, forested areas of moderate terrain for the presence of abandoned wells. These well-finding methods were evaluated at a proposed Marcellus Shale gas drilling site in Washington County, Pennsylvania, where the methods collectively located 18 confirmed wells: 15 wells were identified from aeromagnetic surveys, two wells were identified from inspection of historical air photos, and one well was identified by evaluation of state-wide LiDAR imagery. Only six wells were previously known, and their locations, as recorded in Pennsylvania’s statewide oil and gas wells database (PA/IRIS/WIS), were often too inaccurate for the wells to be found in the dense underbrush. Twelve wells identified in this study were abandoned, unmarked, and undocumented. Aeromagnetic surveys locate wells by detecting the unique magnetic signature of vertical, steel well casing, which is depicted on magnetic maps as a “bull’s eye” type anomaly that is centered directly over the well. However, when wells were drilled and found to be sub-economic, their casing was sometimes pulled and salvaged for reuse. Such wellbores provide no magnetic response and go undetected if all casing was removed. Oftentimes attempts to retrieve well casing were not 100% successful. For example, historical records for one well in the study area indicate that the well was completed in 1902 as a dry hole and that, to the extent possible, the casing was pulled for reuse. However, a section of 10-in. diameter steel casing was not recovered and remains at an unknown depth in the wellbore. This well was easily detected by the aeromagnetic survey although only deep casing remained in the well. To mitigate for the likelihood that wellbores exist where most or all casing has been removed, this study augmented aeromagnetic data with historic air photos and digital terrain models generated from LiDAR datasets—both databases are publicly available at no cost for areas within Pennsylvania. These complementary methods located three wells where the aeromagnetic anomaly, although present, was subtle and overlooked. Together, these methods determined accurate locations for six known wells within the study area and located 12 previously unknown wells. Although it is not certain that these methods successfully located all wells in the study area, the application of these methods does represent a significant improvement over relying on existing databases for well locations. For the Appendix to the report, see: https://www.netl.doe.gov/energy-analysis/details?id=b46c417a-7c9e-4d25-b810-e6248b0217f4</p>

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Online and Offline Data Quality Monitoring for the Mu2e Calorimeter

This thesis presents the design, implementation, and validation of a calorimeter Data Quality Monitoring (DQM) toolchain for the Mu2e experiment at Fermilab. Mu2e searches for charged lepton flavor violation via coherent muon-to-electron conversion in the field of an aluminum nucleus, $\mu^- Al \rightarrow e^-Al$, a process whose observation would constitute clear evidence of physics beyond the Standard Model. Achieving target sensitivity requires stringent control of detector performance and data integrity during acquisition, as subtle issues in readout configuration, data formatting, or electronics behavior can compromise reconstruction and bias downstream analyzes. To address these challenges, this work develops a multi-layer DQM approach spanning both raw data validation and reconstructed digi-level diagnostics. At the low level, a fragment analysis component performs word- and bit-field decoding of calorimeter readout blocks, enabling sanity checks of the expected structure and producing detailed error and integrity statistics useful for commissioning and troubleshooting. At the digi level, the CaloDigiDQM analyzer is implemented within the art framework and transforms each CaloDigiCollection into a structured hierarchy of ROOT histograms designed for fast drill-down diagnostics. The module generates coherent monitoring views at global, disk, board, and channel granularity, including occupancy, waveform-derived features (baseline, RMS, peak amplitude and position), and left-right sensor consistency metrics. Detector-aware channel-to-electronics mapping is performed through the conditions system (CaloDAQMap), ensuring that diagnostics remain aligned with hardware identifiers used in operations. For end-to-end testing without reliance on live DAQ data, a synthetic CaloDigi producer is developed to generate realistic waveforms with controlled noise and pulse shapes. The resulting system supports both offline ROOT-file production and online operation, including optional histogram streaming through otsdaq via ots::HistoSender. This toolchain provides a practical and scalable foundation for calorimeter commissioning and stable data collection, enabling early detection of anomalies and reducing operational risk for Mu2e.

Vakulenko, Mark [Drew U.] (ORCID:0009000276197818)↗