A Review of Fault‐Tolerant Control Applications in Process Equipment: Boilers, Heat Exchangers, Pumps, Turbines, and Engines for Greater Reliability

Process equipment such as boilers, heat exchangers, pumps, turbines, and engines now benefits from applying Fault‐Tolerant Control (FTC), since it improves the system's reliability, safety, and uninterrupted operation under faults. This review assesses how both classical and recent FTC techniques, model‐based, signal‐based, and data‐driven, are used with various kinds of industrial process equipment. The article explores ways such as ultrasonic guided wave testing, infrared thermography, acoustic emission, vibration analysis, and oil analysis to prevent faults from affecting the plant and help with fault isolation. It focuses on how FTC is combined with modern tools like Artificial Intelligence (AI), the Internet of Things (IoT), sliding mode control, adaptive observers, and model‐free control methods. The study also looks at how different FTC schemes function and how well they can accommodate faults. Key issues addressed in this work include problems with real‐time execution, dealing with nonlinear systems, issues related to mixer chattering, expanding neural networks beyond specific areas, and connecting physical systems with computers. Recent examples and studies in the energy, manufacturing, and transportation industries are examined to confirm FTC's real‐world effectiveness. Areas of future interest include AI‐enabled architectures for FTC, seamless use of IoT in FTC, efficient designs for the observer, and different control solutions. The purpose of this review is to assist researchers and experts in developing smart control solutions that can respond to changes and remain stable in the process industries of the future.