The previously developed method for integrated process and control sys
tem (IPCS) synthesis (Hangos et al., 1994) has been extended to the ca
ses for which process safety or reliability is of primary concern. An
unambiguous representation of the resultant integrated process and fau
lt-tolerant control system structure, IPFCS structure in brief, is ren
dered possible through the CP-graph originally proposed for IPCS synth
esis. A new axiom for the fault-tolerant controllability is establishe
d; it states that more than one independent control path are required
for each controlled variable. The fundamental combinatorial algorithm
of IPCS synthesis, i.e., algorithm CMSG, has been revised so that the
modified set of axioms is capable of identifying the controllable, fau
lt-tolerant structures of an IPFCS synthesis problem. The efficacy of
the proposed method for IPFCS synthesis method is demonstrated with a
relatively simple example by systematically varying the level of the f
ault tolerance.