Design of a fault-tolerant control system for a centrifugal pump-based level control system for sensor faults

Irfan, Muhammad, Amin, Arslan Ahmed, Waseem, Saba, Rahman, Saifur, Alwadie, Hatim and Al Dawsari, Saleh 2026. Design of a fault-tolerant control system for a centrifugal pump-based level control system for sensor faults. Scientific Reports 10.1038/s41598-026-42361-x

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Abstract

Industrial activities rely on centrifugal pumps for fluid movement in numerous processes, including water treatment plants and chemical processing plants. These pumps must be used to precisely transfer the specific fluid level in tanks in order for operations to be stable and effective. Nevertheless, typical Proportional Integral Derivative (PID) controllers have the potential to deal with these types of problems, and the feedback measurement is based on sensors. Also, in industrial process control systems, where exact information is vital for maintaining stability and performance across applications, sensor faults are a significant challenge to address. Any issue with the level-measuring sensor could cause unnecessary downtime and incorrect production, which could have a big impact on the control loop. For such systems, this paper suggests a Fault-Tolerant Control (FTC) approach that actively estimates faulty sensor data in real-time using a Fault Detection and Isolation (FDI) estimator. The FDI unit of system estimates a value based on data from other operating sensors in the case of one sensor fault. The results show that the suggested strategy is an effective approach to keep the pump running even if the sensor fails. The control loop is based on an estimate from the FDI unit; thus, it continues to operate even if a sensor fails. Given the numerous industrial applications for centrifugal pumps, the suggested approach guarantees improved efficiency and fault tolerance.

Item Type:	Article
Date Type:	Published Online
Status:	In Press
Schools:	Schools > Engineering
Publisher:	Nature Research
ISSN:	2045-2322
Date of First Compliant Deposit:	23 March 2026
Date of Acceptance:	25 February 2026
Last Modified:	23 Mar 2026 11:00
URI:	https://orca.cardiff.ac.uk/id/eprint/185931

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