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There are high expectations for reliability, safety and fault tolerance are high in chemical plants. Control systems are capable of potential faults in the plant processing systems. This paper proposes is a new Fault Tolerant Control (FTC) system to identify the probable fault occurrences in the plant.

A Fault Diagnosis and Isolation (FDI) module has been devised based on the estimated state of system. An Unscented Kalman Filter (UKF) is the main innovation of the FDI module to identify the faults. A Multi-Sensor Data Fusion algorithm is utilized to integrate the UKF output data to enhance fault identification. The UKF employs an augmented state vector to estimate system states and faults simultaneously. A control mechanism is designed to compensate for the undesirable effects of the detected faults.

The performance of the Nonlinear Model Predictive Controller (NMPC) without any fault compensation is compared with the proposed FTC scheme under different fault scenarios. Analysis of the simulation results indicates that the FDI method is able to identify the faults accurately. The proposed FTC approach facilitates recovery of the closed loop performance after the faults have been isolated.

A significant contribution of the paper is the design of an FTC system by using UKF to estimate faults and enhance the accuracy of data. This is done by applying a data fusion algorithm and controlling the system by the NMPC after eliminating the effects of faults.