Continuous online validation of process measurements in digital twins

A non-transitory, computer-readable medium storing one or more instructions executable by a computer system to perform operations comprising:

• monitoring readings of actual field sensors corresponding to virtual sensors modeled in a virtual model;
• determining a deviation between an actual sensor reading (ASR) and a virtual sensor reading (VSR);
• when only the VSR is deviating and when sensor readings of sensors that are proximate to the actual sensor correspond to the VSR, then:
• determining that the ASR is invalid and that the actual sensor requires revalidation and recalibration;
• when only the ASR is deviating and when sensor readings of sensors that are proximate to the actual sensor correspond to the ASR, then:
• determining that the VSR is invalid and that the virtual sensor requires revalidation and recalibration;
• and
• when both of the VSR and the ASR are deviating from their respective design ranges and when sensor readings of sensors that are proximate to the actual sensor do not correspond to either the ASR or the VSR, then:
• determining that both the ASR and the VSR are invalid and that both the actual sensor and the virtual sensor require revalidation and recalibration.

A computer-implemented system, comprising:

• one or more processors;
• and
• a non-transitory computer-readable storage medium coupled to the one or more processors and storing programming instructions for execution by the one or more processors, the programming instructions instructing the one or more processors to perform operations comprising:
• monitoring readings of actual field sensors corresponding to virtual sensors modeled in a virtual model;
• determining a deviation between an actual sensor reading (ASR) and a virtual sensor reading (VSR);
• when only the VSR is deviating and when sensor readings of sensors that are proximate to the actual sensor correspond to the VSR, then:
• determining that the ASR is invalid and that the actual sensor requires revalidation and recalibration;
• when only the ASR is deviating and when sensor readings of sensors that are proximate to the actual sensor correspond to the ASR, then:
• determining that the VSR is invalid and that the virtual sensor requires revalidation and recalibration;
• and
• when both of the VSR and the ASR are deviating from their respective design ranges and when sensor readings of sensors that are proximate to the actual sensor do not correspond to either the ASR or the VSR, then:
• determining that both the ASR and the VSR are invalid and that both the actual sensor and the virtual sensor require revalidation and recalibration.