Methods and apparatus to implement predictive analytics for continuous control system processes

A non-transitory computer readable medium comprising instructions that, when executed, cause a machine to at least:

• generate a first pool of historical sampling batches based on historical process data of a first instance of a continuous control system process, a portion of the historical process data associated with at least one of a startup period or a shutdown period of the first instance of the continuous control system process;
• generate an analytical model based on the first pool of historical sampling batches;
• validate the analytical model based on a second pool of historical sampling batches;
• implement a sampling batch on a virtual batch unit, the virtual batch unit to run in parallel with a second instance of the continuous control system process, the sampling batch corresponding to a discrete period of time of the second instance of the continuous control system process, the discrete period of time being shorter than a duration of the second instance of the continuous control system process, the continuous control system process implemented using a continuous process control system, the continuous process control system being different than a batch process control system, the virtual batch unit including input and output parameters corresponding to parameters associated with the continuous control system process;
• designate values for initial conditions of the virtual batch unit, different ones of the initial conditions corresponding to different ones of the parameters associated with the continuous control system process, the values for the initial conditions corresponding to values of the parameters associated with the second instance of the continuous control system process at a start of the discrete period of time, the initial conditions being a separate set of inputs for the virtual batch unit that are distinct from the input parameters, the initial conditions to remain fixed throughout the implementation of the sampling batch;
• and
• generate predictive analytic information indicative of a predicted quality of an output of the second instance of the continuous control system process at an end of the discrete period of time based on an analysis of the sampling batch relative to the analytical model, the predictive analytic information to facilitate at least one of maintenance or improvement of at least one of safety, performance, or efficiency of the second instance of the continuous control system process.

A method comprising:

• generating a first pool of historical sampling batches based on historical process data of a first instance of a continuous control system process, a portion of the historical process data associated with at least one of a startup period or a shutdown period of the first instance of the continuous control system process;
• generating an analytical model based on the first pool of historical sampling batches;
• validating the analytical model based on a second pool of historical sampling batches;
• implementing, by executing instructions with at least one processor, a sampling batch on a virtual batch unit, the virtual batch unit to run in parallel with a second instance of the continuous control system process, the sampling batch corresponding to a discrete period of time of the second instance of the continuous control system process, the discrete period of time being shorter than a duration of the second instance of the continuous control system process, the continuous control system process implemented using a continuous process control system, the continuous process control system being different than a batch process control system, the virtual batch unit including input and output parameters corresponding to parameters associated with the continuous control system process;
• designating, by executing the instructions with the at least one processor, values for initial conditions of the virtual batch unit, different ones of the initial conditions corresponding to different ones of the parameters associated with the continuous control system process, the values for the initial conditions corresponding to values of the parameters associated with the second instance of the continuous control system process at a start of the discrete period of time, the initial conditions being a separate set of inputs for the virtual batch unit that are distinct from the input parameters, the initial conditions to remain fixed throughout the implementation of the sampling batch;
• and
• generating, by executing the instructions with the at least one processor, predictive analytic information indicative of a predicted quality of an output of the second instance of the continuous control system process at an end of the discrete period of time based on an analysis of the sampling batch relative to the analytical model, the predictive analytic information to facilitate at least one of maintenance or improvement of at least one of safety, performance, or efficiency of the second instance of the continuous control system process.