GPUAlert: A Zero-Instrumentation Process-Boundary Monitor for Diagnosing GPU Training-Job Failures

Large-scale AI training is fundamentally a distributed systems problem, where hardware failures are routine operating conditions rather than rare exceptions, yet public operational evidence from production training clusters remains limited. This report presents an empirical analysis of a 63-node NVIDIA B200 production cluster (504 GPUs), using 55 days of Prometheus time-series data and 73 days of operational logs covering 224 multi-node training sessions. The environment is cross-organizational: five parties (SKT, Upstage, Lablup, NVIDIA Korea, VAST Data) share a unified monitoring pipeline. This enabled joint diagnosis of a 60-node-scale storage I/O bottleneck absent in 2-4-node tests, a production-scale phenomenon no single team could isolate alone. We perform three quantitative analyses yielding four findings. First, over 751 Prometheus metrics and 10 XID-identified GPU failures, no single metric is consistently dominant across failure types, motivating multi-signal detection. Second, 523 checkpoint events trace the save/load path from GPU VRAM to the NFS server: restart loading reaches 21.5% of maximum read bandwidth (700 GB/s) and save bursts 16.0% of maximum write bandwidth (250 GB/s), with NFS/RPC queueing and transport-layer backlog rising together. Third, across 224 sessions over 73 days, node exclusions concentrate so the top 3 of 63 nodes account for over 50%. Fourth, auto-retry chain analysis shows a 33.3% success rate over 12 chains (73 attempts), 2.7x the 12.5% manual rate, with a median retry interval of 11 minutes (IQR 10-11). All analyses are grounded in production infrastructure providing session-level workload management, GPU-centric scheduling, and unified observability.

Hardware-enabled monitoring of GPU workloads underpins many proposals for AI compute governance, but if developers can defeat monitoring mechanisms, such schemes are unworkable. We evaluate the adversarial robustness of GPU workload classification using only zero-overhead, privacy-preserving NVML telemetry: content-agnostic signals that observe physical effects of computation without accessing model weights, training data, or hyperparameters. Across 5 rounds of monitor-evader iteration, we evaluate 20 evasion strategy families on 9 GPU models spanning 4 architecture generations. We develop a classifier that achieves 98.2% binary accuracy at identifying training workloads across the whole corpus, and 43-87% accuracy against the most challenging unexpected workloads even when they are adversarially disguised.

Pre-training large language models on massive GPU clusters has made hardware faults routine rather than rare, driving the need for resilient training systems. Yet existing frameworks either focus on specific parallelism schemes or risk drifting away from a failure-free training trajectory. We propose ReCoVer, a resilient LLM pre-training system that upholds a single invariant: each iteration keeps the number of microbatches constant, ensuring per-iteration gradients remain stochastically equivalent to a failure-free run. The framework is organized as three decoupled protocol layers: (1) Fault-tolerant collectives that isolate faults from propagating across replicas; (2) in-step fine-grained recovery that preserves intra-iteration progress and prevents gradient corruption; (3) versatile-workload policy that dynamically redistributes microbatch quotas across the survivors. The design is parallelism-agnostic, integrating directly with both 3D parallelism and Hybrid Sharded Data Parallel (HSDP) as a drop-in substrate. We evaluate our implementation on end-to-end pre-training tasks for up to 512 GPUs, ReCoVer successfully preserves the training trajectory from a failure-free reference despite of 256 GPUs lost spread across the run. For comparison with checkpoint-and-restart baselines, ReCoVer demonstrates $2.23\times$ higher effective throughput after successive failures. This advantage results in ReCoVer processing 74.9% more tokens at 234 GPU-hours, with the gap widening as the training prolongs.