A Tutorial on Autonomous Fault-Tolerant Control Using Knowledge-Grounded LLM Agents

We propose an agentic Large Language Model (LLM) framework for active Fault-Tolerant Control (FTC) that transforms fault detection outputs into constraint-aware recovery actions grounded in plant-specific knowledge. The approach couples (i) a multi-agent workflow that decomposes operator duties into monitoring, planning, action synthesis, simulation, validation, and reprompting; (ii) a Digital Process Plant Twin (DPPT) that exposes plant data, models, and a simulation service for pre-execution testing; and (iii) a Graph Retrieval-Augmented Generation (Graph RAG) layer built on the CPSMod ontology, which organizes plant knowledge (structure, function, hybrid dynamics, control context, and fault semantics) into a graph that supports relation-aware, multi-hop retrieval for the agents. Corrective actions are generated as minimal-risk state-machine recovery paths and corresponding discrete commands or continuous setpoint adaptations, then validated deterministically against interlocks, envelopes, and dynamic feasibility before any actuation. If no acceptable plan is found within a bounded time window, control is handed to a safety fallback. The framework is evaluated in simulation on two representative benchmarks: a discrete batch Mixing Module and a Continuous Stirred-Tank Reactor (CSTR) under closed-loop PID regulation. Results with lightweight LLMs (GPT-4o-mini and GPT-4.1-mini) show that semantically grounded agents can derive valid recovery decisions within latency budgets compatible with the respective process dynamics, demonstrating a practical pathway from detection to validated corrective action across both discrete and continuous FTC tasks.

LLM-based agents can recover from individual execution errors, yet they repeatedly fail on the same fault when the underlying process knowledge--operator schemas, preconditions, and constraints--remains unrepaired. Existing self-evolving approaches address this gap by updating prompts, memory, or model weights, but none directly repair the symbolic structures that encode how tasks are executed, and few provide the governance guarantees required for safe deployment. We introduce ANNEAL, a neuro-symbolic agent that converts recurring failures into governed symbolic edits of a process knowledge graph without modifying foundation model weights. Its core mechanism, Failure-Driven Knowledge Acquisition (FDKA), localizes the responsible operator, synthesizes a typed patch through constrained LLM generation, and validates the proposal via multi-dimensional scoring, symbolic guardrails, and canary testing before commit. Every accepted edit carries full provenance and deterministic rollback capability. Across four domains and 27 multi-seed runs, ANNEAL is the only evaluated system that commits persistent structural repairs--strong baselines such as ReAct and Reflexion achieve high episodic recovery yet retain 72--100% holdout failure rates on recurring faults, whereas ANNEAL reduces these to 0% in the tested recurring-failure settings. Ablation confirms that removing FDKA eliminates all structural repairs and drops success rate by up to 26.7 percentage points. These results suggest that governed symbolic repair offers a complementary paradigm to weight-level and prompt-level adaptation for persistent fault elimination.

Tool-augmented large language model (LLM) agents rely on orchestration layers that coordinate planning, retrieval, tool invocation, validation, memory, and recovery. In these systems, failures arise not only from model errors, but also from orchestration-level issues such as tool timeouts, malformed arguments, stale context, contradictory evidence, retry loops, and unverified intermediate outputs. This paper presents a self-healing agentic orchestrator that treats reliability as a bounded runtime control problem. The orchestrator maps observable failure signals to inferred failure classes, selects targeted recovery actions under explicit budgets, verifies recovered trajectories, and records observability traces. We evaluate the approach on a 100-task controlled fault-injection benchmark against static workflow, retry-only, ReAct-style, and full-replanning baselines. Self-healing achieves 98.8% task success, compared with 94.5% for retry-only and 93.8% for full replanning. A matched recovery-budget sweep shows that self-healing outperforms retry-only and full replanning at every tested budget, with the largest gap under a single recovery attempt: 94.0% versus 85.3% and 88.2%, respectively. Under a controlled semantic silent-failure setting, verifier-guided self-healing reduces silent failures to 0.0%, while non-verifying baselines return wrong-but-plausible outputs more often. A compact model-in-the-loop validation shows that the same recovery mechanism can operate when a live tool-calling model performs tool selection, argument generation, and answer synthesis over local fault-injected tools. These results provide controlled evidence that failure-aware, budgeted, and verification-guided orchestration improves reliability and diagnosability in tool-augmented LLM systems.