The increased complexity of plants and the development of sophisticated control systems have necessitated the parallel development of efficient Fault Detection and Isolation (FDI) systems. This paper discusses a model based technique, viz., observers for detecting and isolating parametric and sensor faults. In this paper, a novel diagonal nonlinear residual feedback observer is proposed which is valid for a certain class of nonlinear systems where, subject to other conditions, the state depends nonlinearly on the fault. A number of typical chemical engineering systems can be represented by models of this form. The structure of the observer ensures that the residuals are diagonally affected by the faults. Conditions for exact decoupling of residuals are presented and convergence of the observer in the presence of step faults is proved using Lyapunov like analysis. Multiple observers and a decision logic module are used for FDI when there are un-monitored faults. Results are presented from numerical simulations of an illustrative example and a typical chemical engineering system: a counter-current heat exchanger. (c) 2008 Elsevier Ltd. All rights reserved.