Systems and methods for using intermediate data to improve system control and diagnostics

A system comprising:

• a process control system configured to:
• monitor intermediate data and correlation data;
• store historical data sets associated with the intermediate data and historical data sets associated with the correlation data;
• generate a first model that defines a relationship between the historical data sets associated with the intermediate data and the historical data sets associated with the correlation data;
• compare the first model with a second model defining a nominal relationship between real-time data inputs associated with the intermediate data and real-time data inputs associated with the correlation data;
• predict a state of a heater system based on the comparison between the first model and the second model;
• and
• selectively perform a corrective action based on the predicted state of the heater system.

One or more non-transitory computer-readable media storing processor-executable instructions that, when executed by at least one processor, cause the at least one processor to:

• monitor intermediate data and correlation data;
• store historical data sets associated with the intermediate data and historical data sets associated with the correlation data;
• generate a first model that defines a relationship between the historical data sets associated with the intermediate data and the historical data sets associated with the correlation data;
• compare the first model with a second model defining a nominal relationship between real-time data inputs associated with the intermediate data and real-time data inputs associated with the correlation data;
• predict a state of a heater system based on the comparison between the first model and the second model;
• and
• selectively perform a corrective action based on the predicted state of the heater system.