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  • https://doi.org/10.2118/231879-msCopy DOI Icon

Physics-Informed Machine Learning for Anomaly Detection in Subsurface Sensor Data and Automated Reporting

  • Apr 21, 2026
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Abstract

Abstract The Interval Control Valve (ICV) tool goes through a rigorous bench-test called the System Integration Test (SIT) to ensure the tool is safe for use before downhole deployment. The data from each sensor is stored in separate streams. Manual analysis of this high-volume stream data (often up to ∼300k data points) is time-consuming and usually involves visual judgement of the traces, which is prone to inconsistency and mistakes. This paper aims to automate anomaly detection and compliance reporting to improve speed, accuracy, and repeatability of SIT validation. A physics-informed ensemble machine learning (ML) system was developed to automate the process of detecting anomalies for the subsurface ICV tool during SIT. An ensemble of 10 models was trained on unlabeled SIT data. This ensemble comprises both Isolation Forest and XGB residuals machine learning models. A web application was built that ingests data directly from the data source in the cloud, displays the analysis on a dashboard interface, and enables one-click PDF report generation. The ensemble achieved high accuracy; the physics-guided feature selection proved successful with the model achieving a mean F1 score of 0.93. Notably, a simple delta Temperature-based Isolation Forest outperformed more complex models in detecting seal leakage (F1 = 0.99), underscoring the value of domain knowledge in anomaly detection. The system demonstrated operational efficiency, batch processing ∼30k datapoints in 58 seconds with only 14 MB memory usage, making it lightweight enough for deployment without GPU resources. Detected anomalies included power drops, jittering choke positions, and temperature divergence, all of which correlate with failure modes identified by engineers. By automating SIT review, the system reduces analysis time from hours to minutes and ensures standardized, auditable documentation. The results highlight how lightweight ML models can accelerate SIT workflows, improve tool qualification, and reduce the risk of faulty tools reaching deployment. This work presents one of the first physics-informed ensemble ML systems applied to SIT of downhole completion tools. Unlike previous studies focusing on production surveillance, this solution targets the qualification stage, bridging anomaly detection with automated reporting.

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