Professional Documents
Culture Documents
Standards
Certification
Education & Train ing
Publishing
"J
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) Study Guide
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The CAIJ Study Guide is designed to provide a review of key content areas
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(domains) covered on the CAP examination and to familiarize the applicant with
the type of questions that may be covered. Actual CAP examination questions are
not available in the public domain and are not included in this study guide.
Satisfactory completion of study guide questions in no way assures a passing score
on the CAP examination.
ISA -2007
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Table of Contents
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Introduction
Domain 1: Feasibility Study- identify, scope, and justify the automation project
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CAP Resources
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WELCOME
Thank you for your interest in the ISA
Certified Automation Professionals'
(CAJ:') Program. The CA.P program
recognizes your experience, knowledge,
and education in automation - and
provides objective, third-party
endorsement of your skills. Certification
from ISA demonstrates your
commitment to your future, establishes
your credentials as an automation
professional, and opens career
opportunities.
This self-study guide was developed
to help you prepare for the ISA CAP
exam. The CAP Introduction below will
provide you with information about the
Program.
The CAP Study Guide is divided into
six domains to reflect the structure of the
exam. Each domain consists of a
performance domain name and task list,
sample questions, and an answer key,
complete with justifications and a cited
reference. Recommended sources for
study are noted in a resource list.
Although the questions in this guide
reflect questions on the exam,
completing this guide is no guarantee of
achieving certification. The best way to
prepare for the exam is to study as much
information relative to the domains and
tasks as possible.
www.isa.org/CAP
Program Definition
An ISA Certified Automation
Professional (CAP) has completed a
four-year technical or technology
degree and five years of experience
working in automation. CAPs are
responsible for the direction, definition,
design, development! application,
deployment, documentation, and
support of systems, software, and
equipment used in control systems,
manufacturing information systems,
systems integration, and operational
consulting.
The written CAP examination is a
measure of a candidate's general and
basic skills and knowledge of the
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CAP PROGRAM
REQUIREMENTS &
DOCUMENTATION
The CAP examination is only one
requirement for certification. The
candidate must also meet minimum
requirements comprised of work
experience and education. The
qualification requirements for the
certification are described in detail
below. During the initial two years of
the CAP program (2005 - 2006), the
four year degree requirement will be
waived for automation professionals
who have been working in the
automation field for ten (10) or more
years.
General criteria to qualify to take the
CAP examination include a
commitment to the ISA Code of Ethics
(see Introduction, page XI), a completed
application with documentation
included to support the education and
experience requirements, and the
application fee. Applicants must meet
the qualifications outlined in either
section I or II below to be eligible to sit
for the CAP exam.
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II
Verification of Employment
Work experience and educational
periods may not overlap when
compiling the total number of years
required for this certification.
Applicants must submit
completed Verification of
Employment forms for all employers
or provide equivalent
documentation. All forms must be
signed by the supervisor. An
applicant with military experience in
the related technologies defined for
the CAP program must document
this period by submitting a copy of
his or her DD 214 form accompanied
by a written description of this
experience. An official college
transcript is also required.
For employers that may be
unavailable to provide first-hand
verification, a two-party verification
of the employment must be provided
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RENEWAL
CAPs will be required to renew
their certification every three years.
If you do not renew within 4 months
after your expiration date, your
certification is considered lapsed. In
order to renew, documentation of
work experience in automation
during the time certified will be
required, as well as documentation
of continuing education. A total of
135 Professional Development Points
(PDPs) are required to renew your
certification. The PDPs can be earned
as follows:
Work experience in automation
(30 PDPs each year). A minimum of
60 PDPs (2 years) must be obtained
EXAMINATION
A comprehensive job analysis
was conducted in 2004 to account for
the work performed by CAPs. The
job analysis identified performance
domains that were subsequently
validated in a nationwide survey.
Exam.questions are also distributed
by knowledge or technical topic
categories.
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IV
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Feasibility Study
Definition
System Design
Development
Deployment
Operation and
Maintenance
% of Questions
12%
15%
25%
22%
15%
11%
3
4
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Basic Continuous 14 %
Control
Discrete,
13%
Sequencing, and
Manufacturing
Control
Advanced Control 9%
Reliability, Safety 13 %
and Electrical
Integration and
21 %
Software
Deployment and 16%
Maintenance
Work Structure
14 %
www.isa.org/CAP
2008 Application
Postmark Deadlines
Window 1:
1 March - 30 April
Window 2:
1 July - 31 August
Window 3:
1 November - 31
December
Tuesday,
15 January
Thursday,
15 May
Monday,
15 September
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Examination Fees
Currently, the application fee is
$250.00 for ISA Members and $295.00
for non-members. This fee is subject
to change. The fee must be paid in
U.S. funds. ISA will accept a check,
certified check, money order, or
credit card. Purchase orders are not
accepted. Payment must be received
with the application before it will be
processed.
COMPLETING THE
APPLICATION
Candidates must complete all
sections of the application. The
application is available as a
downloadable PDF file at
www.isa.orglCAP. You may also
contact ISA at cap@isa.org or (919) 5498411 to request a copy.
Section A: Applicant Information
Provide complete contact
information as requested. If ISA has
a different mailing address on file for
you, it will be changed to this
preferred mailing address. All ISArelated materials will be mailed to
this address unless you specify
otherwise.
Indicate if you suffer from a
disability or religious obligation that
would require an accommodation for
test administration. Provide a
written explanation of the
accommodation you request.
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ISA
CAP Program
P.O. Box 3561
Durham, NC 27702
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www.isa.org/CAP
V lJI
Appeals
A. All appeals shall be in writing.
1. The notice of appeal must be delivered to the Certification Board,
addressed to the attention of the ISA Executive Director, by the close of
business on the 21st day after the date of the notice of denied certification.
2. The appeal should include the date the notice of denied certification was
received and must state the reasons the applicant believes the denied
certification was in error.
3. The appeal should indicate whether or not the applicant requests a
hearing.
a. If a hearing is requested, the applicant must explain why a hearing is
needed, identify the issues to be resolved at a hearing, list names of
prospective witnesses, and identify documentation and other evidence
to be introduced at the hearing before the Board.
4. The Chair of the Certification Board will select a three-member panel of
the Board to become the Review Panel, one of whom shall be appointed
Chair and will be the final vote in the event of a tie during the ruling.
II. Procedures
A. The Review Panel will review the appeal and any request for a hearing. The
Review Panel will grant a hearing in connection with the appeal, if requested.
1. Hearing
a. The Chair of the Review Panel will determine the time and location of
the hearing within 90 days after determination that a hearing is
warranted and will notify the applicant within the first 21 days. The
applicant will be notified of the hearing time and location at least 20
days prior to the time determined for the hearing.
b. The applicant may be represented by counselor represent him/herself
at the hearing. The applicant may offer witnesses and documents and
may cross-examine any witness.
c. The Review Panel may consider any evidence it deems relevant
without regard to strict application of legal rules of evidence.
d. The applicant is urged to submit a written brief (four copies) 10 days
prior to the hearing to the Certification Board, addressed to the
attention of the ISA Executive Director, for distribution to the panel in
support of his/her position. However, written briefs are not required.
www.isa.org/CAP
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2. Deposition
i. If the applicant or Review Panel desires to take a deposition prior
to the hearing of any voluntary witnesses who cannot attend the
hearing, the deposition of a witness may be applied for in writing
to the Chair of the Review Panel together with a written consent
signed by the potential witness that he or she will give a deposition
for one party and a statement to the effect that the witness cannot
attend the hearing along with the reason for such unavailability.
ii. The party seeking to take the deposition of a witness shall state in
detail as to what the witness is expected to testify.
iii. If the Chair of the Review Panel is satisfied that such deposition
from a possible witness will be relevant to the issue in question
before the Panel, then the Chair will authorize the taking of the
deposition. The Chair will also designate a member of the Panel to
be present at the deposition.
iv. The deposition may be taken orally or by video. Any refusal of the
taking of the deposition by the Chair shall be reviewed by the Panel
at the request of the applicant.
v. The party requesting the deposition will pay for the cost connected
with taking the deposition.
B. The applicant will be notified of the result of the Review Panel within 30 days
of the meeting.
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III.
Final Review
A. If the Review Panel makes a decision adverse to the applicant, the applicant
may appeal to the full Certification Board for a final review by the close of
business on the 21st day after the notice of decision is issued. Such appeal
shall follow the same procedures as the initial appeal to the extent possible
with the Chair of the Board serving as the Chair of the Final Review Panel.
The Chair will once again select a three-member panel, one of whom shall be
himself, to become the Review Panel, and the final vote in the event of a tie
during the ruling shall be his.
B. If the applicant does not petition the Board for review or request a hearing
before the Board regarding the recommendation of rejection of the
application within the time allowed by these rules, the original decision by
the Review Panel shall stand.
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www.isa.org/CAP
Article III
Members shall issue public
statements only in an objective and
truthful manner, and shall include
all pertinent and relevant
information in professional reports,
statements and testimony. Members
shall be honest and realistic in
making estimates or in stating
claims based on available data.
Members shall offer honest criticism
of work, and shall properly credit
the contributions of others.
Article IV
Members shall act in professional
matters for each employer or client
as faithful agents or trustees, and
shall not participate in any business
association, interest or
circumstances which influence, or
appear to influence, their judgment
or the quality of their services.
Members shall accept
compensation, financial or
otherwise, from only one party for
services on or pertaining to the
same work, unless otherwise agreed
to by all parties; and shall not give
or accept, directly or indirectly, any
gift, payment or service of more
than nominal value to or from those
having business relationships with
their employers or clients.
Article V
Members shall use only proper
solicitation of employments, and
shall represent their abilities,
qualifications, education, technical
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Article VI
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2. Make professional contacts and open the door to your future by partici-pating in
Technical Divisions and other networking activities, such as local Section meetings,
conferences, and symposia.
3. Receive valuable money-saving discounts on all ISA training courses, books, videos,
and CD-ROMs.
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4. Shop smarter by using the ISA DirectonJ- ISA's exclusive annual guide of products,
specifications, manufacturers, sales offices, services, and more.
5. Keep up with industry standards and practices. As an ISA Member, you receive one
free standard per membership year.
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Get ahead by getting involved in ISA. To join ISA, complete an ISA Membership
enrollment form and return it with your CCST Application, or call (919) 549-8411.
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Feasibility Study
PERFORMANCE DOMAIN I
FEASIBILITY STUDY
Ide1ltifrJ, scope, and justifrJ the automation project
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Feasibility Study
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A. Feedforward
B. Feedback
C. Cascade
D.Openloop
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3. Given the following diagram, what is the transfer function for C(s)jR(s)?
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R(s) ,-
---.t
t----r---+ C( s)
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B.
GcGpcG/,
I + GcGpcG p
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GCGpCGpGM
1+ GcGPCG /,GM
D.
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Feasibility Study
4. MOST initial project budgetary cost estimates have an acceptable margin of error of
plus or minus:
A.10%
B.30%
C. 50%
D.70%
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Feasibility Study
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Gathering requirements is important because they define the objectives, purpose, scope,
needs, and other key meters. They perform the basis for understanding for the
customer, the engineer, and other stakeholders. Requirements may make it easier to get
funding approval and stakeholder approval but only because the purpose, scope, and
objectives are included. Gathering requirements should not affect the ease of
calculation.
Requirements will not be generated automatically and should be mapped out before an
automation project begins.
Reference:
Parshall & Lamb. Applying 588: Batch Control from a User/ s Perspective. ISA,2000.
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2. A. Feedforward
A. Feedforward
B. Feedback
C. Cascade
D.Openloop
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Reference:
Smith and Corripio. Principles and Practices of Automatic Process Control, 2nd Edition.
Wiley & Sons, 1997.
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3. A.
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The numerator is the product of the transfer functions between the input and output
which are "R" and "C," respectively in this case. The denominator is one plus the
product of all the transfer functions.
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Reference:
Ellis. Control System Design Guide, 3 rd Edition. Academic Press, 2000.
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Feasibility Study
4. B. 300/0
It's commonly accepted to have a preliminary estimate with a margin of error of plus or
minus 30%. A more detailed estimate is done before the bid is presented to reduce the
margin of error to 10%.
Reference:
Whitt. Successful Instrument and Control System Design. ISA, 2004.
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Definition
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PERFORMANCE DOMAIN II
DEFINITION
ldentifiJ customer requirements and complete high-leoel analusi of tire best way to meet
those requirements
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Definition
An
An
An
An
2. To MINIMIZE the effect of feed upsets to the top of a distillation column, the flow
feed forward signal should be connected to a tray temperature controller output that
then directly manipulates a(n):
A.
B.
C.
D.
3. What is the MOST appropriate technique for modeling linear relationships for a
large number of correlated inputs where the equations are unknown?
A. Artificial neural networks
B. Multivariable statistical process controls
C. Step response models
D. First principle models
4. What is required to find the MOST efficient operating points that are highly
dependent on complex shifting process conditions, such as equipment fouling?
A.
B.
C.
D.
5. What is the recommended limitation in meters for the length of a "fast Ethernet" (100
mbs) segment on twisted pair cable?
A.10
B. 100
C. 300
D.350
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Definition
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A.
B.
C.
D.
Cost plus
Fixed price
Time and material
Unit price
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Definition
1. D.
Reference:
Haynes. Effective Meeting Skills. Crisp, 1998.
2. C. Reflux Controller
A distillation tower, such as that shown in Figure 9-3a p317 of Advanced Control
Unleashed (2003), has feed upsets that are measured and used to create a feedforward
signal. A reflux flow controller remote setpoint becomes the feed multiplied by a refluxto-feed ratio that will be corrected by the temperature controller output. This is the most
linear and accurate way of maintaining the material balance as long as the flow
measurements are above their low range ability limit.
Changes in the pressure drop of a linear reflux valve and the valve installed
characteristics and deadband will introduce errors into the feedforward. Manipulating a
pressure controller setpoint will not set up a flow ratio to maintain the material balance.
A ratio controller uses a ratio of flows as its controlled variable. This creates a nonlinear
loop. Also, the remote set point as started would be incorrect and steam would have a
slower, and generally smaller, effect than reflux flow on the top.
Reference:
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA,2003.
Definition
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The question implies that relationships to find optimum operating points are buried in
the process and change with time. Real-time optimization uses a reconciled high fidelity
process model with the equipment details, such as heat transfer coefficients and
physical properties of the components. Tactical schedulers don't have process
knowledge built in and may request operating points that are not achievable or
advisable based on equipment and process constraints. A linear program assumes fixed
economic relationships and doesn't deal with stationary behavior shifts and nonlinear
process behavior. A model predictive control with a constraint pusher is only able to do
a simple maximization on minimization of a process variable such as feed flow.
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Reference:
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA, 2003.
5. B. 100
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Because of the high speed of "fast Ethernet," the use of twisted pair cable is limited to
100 meters (330 feet). 10 meters would limit installations unnecessarily. 300 meters and
350 meters would exceed recommendations substantially, which could potentially cause
signal errors.
Reference:
Berge. Fieldbuses for Process Control: Engineering, Operation, and Maintenance.
ISA,2001.
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Reference:
NFPA. NFPA 79, NFP A. 2002.
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Definition
7. B. Fixed price
A fixed-price contract is estimated by the supplier and agreed to by the customer before
the project begins. Any overruns are the responsibility of the supplier. In cost plus, time
and material, and unit-price contracts, the supplier and customer agree on the margin-not the total cost of the project.
Reference:
Albert and Coggan. Fundamentals of Industrial Control, 2nd Edition. ISA, 2004.
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System Design
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Design, specifi], and procure the hardtoare / software used in the system
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Task 4: Define the data structure layout and data flow model considering the
volume and type of data involved in order to provide specifications for
hardware selection and software development.
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Task 7: Design the test plan using chosen methodologies in order to execute
appropriate testing relative to functional requirements.
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System Design
Task 8: Perform the detailed design for the project by converting the
engineering and system design into purchase requisitions, drawings, panel
designs, and installation details consistent with the specification and functional
descriptions in order to provide detailed information for development and
deployment.
Task 9: Prepare comprehensive construction work packages by organizing the
detailed design information and documents in order to release project for
construction.
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System Design
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A.
B.
C.
D.
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3. If you need an enclosure that resists corrosion and provides protection for outdoor
use, dust, and hose-directed water, which type of enclosure would you select?
A.
B.
C.
D.
Type 1 (NEMA 1)
Type 4x (NEMA 4x)
Type 12 (NEMA 12)
Type 13 (NEMA 13)
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4. Which of the following control valve body styles is MOST likely to develop blockage
in a paper pulp slurry service?
A.
B.
C.
D.
Pinch
Characterized ball
Butterfly
Globe
5. According to the NFPA 79, the standard wire colors for line voltage, AC control
currents, DC control circuits, and interlock circuits are respectively shown as:
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D.
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System Design
6. R=rL/A
What is the resistance of 1000 ft of copper wire (specific resistance = 10.37) given a
cross-sectional area of 10370 emil and a wire temperature of 200 C ?
A. In
B. 2n
C. Ion
D. loon
e.
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System Design
1.
C. IEC 61508
According to IEC 61511-1, embedded software which is part of the safety device/
controller should follow software guidelines in IEC 61508-3. IEC 61511 and ANSI/ISA
S84 are system standards and not a product standard. 20 CFR Part 11 is not relevant as it
deals with electronic signature.
Reference:
IEC 61511. IEC,2003.
3. B. Type4x (NEMA4x)
NEC 2002 defines an enclosure type 4x as ideal for outdoor use and resistant to splashing
water, windblown dust, hose directed water, and corrosion. It is also undamaged by the
formation of ice on the enclosure. A type 1 enclosure is for indoor use. A type 12
enclosure is for indoor use and resists only dust and dripping non-eorrosive liquids. A
type 13 enclosure is for indoor use and resists dust, spraying water, oil, and non-corrosive
coolants.
Reference:
Earley. NEC 2002 Handbook. NFPA,2002.
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System Design
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4. D. Globe
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A globe valve consists of a plug on the end of a stem that moves the plug onto a seat.
Because of the body design of this valve, cavities in the body can easily fill with materials
and develop blockage. Ball-, butterfly-, and pinch valve body style have straight-through
flow, which is less likely to develop blockage.
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Reference:
Liptak. Instrument Engineers' Handbook - Process Control, Volume 2. CRC Press, 2001.
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Black, red, blue, yellow is the correct answer per NFPA-79: The Electrical Standard for
Industrial Machinery, which is in correspondence with article 670 in the National
Electrical Code (NEC). This is located in section 14.2: Identification of Conduction.
Reference:
NFPA-79: Electrical Standard for Industrial Machinery. NFPA, 2002.
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6.
A. 1 n
The resistance of a length (L) of a conductor can be determined using the specific
resistance and the cross-sectional area (A) in emil by using the equation R = rLI A. 1 Q is
the correct answer.
Reference:
Hughes. Programmable Controllers. ISA, 2001.
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7. C. 100%
The torque of a motor is controlled by the volts per hertz ratio (V1Hz). As long as this
ratio is kept in proportion with the nameplate rating, the motor will develop rated torque.
The only answer that represents rated torque is 100% rated torque. The other values do
not represent rated torque.
Reference:
Polka. Motors and Drives - A Practical Technology Guide. ISA, 2003.
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System Design
8.
The fact that the tank is horizontal implies that the angle of the beam will be narrow at
the surface and the vessel walls will not interfere. Radar can detect the smallest change in
surface level. It does not depend upon the temperature or composition of the fluid as long
as the beam is narrow and the dielectric constant of the fluid is greater than 2. Ultrasonic
level detectors are affected by changes in the speed of sound with temperature and are
not quite as sensitive as radar. Capacitance level detectors are affected by changes in the
dielectric constant with composition and are not quite as sensitive as radar. Differential
pressure transmitters are affected by changes in liquid density with composition and
temperature and are not as sensitive as radar.
Reference:
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA, 2003.
10. B. 16-bits
Common Modbus uses two 8-bit bytes for each data register.
2 x 8 bits = 16 bits
To achieve more precision special programming or a specialized version of Modus would
be needed. Eight-bits is less precise than 16-bits. 24-bits and 30-bits require uncommon
means to achieve.
Reference:
Liptak. Instrument Engineers Handbook - Volume 3 (3rd Edition). Process Software and
Digital Networks. ISA, 2002.
www .isa.org/CAP
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System Design
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The PID term as described refers to the loop control technique used in controllers.
Proportional Integral Derivative is the correct term as referenced. A PID Control Loop
includes proportional, integral, and derivative functions to control the process.
)
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Reference:
Erickson and Hedrick. Plantwide Process Control. Wiley, 1999.
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}
13. A. Single-element
Single element fuses have a very high speed of response to overcurrents. They provide
excellent short-circuit component protection. Dual-element and time-delay fuses can be
applied in circuits subject to temporary motor overloads and surge currents. Dualelement and time-delay fuses contain two series elements-- a short-circuit element and an
overload element.
Reference:
Bussmann Cooper Industries. SPD Electrical Production Handbook.. 1992.
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Development
PERFORMANCE DOMAIN IV
DEVELOPMENT
Software development and coding
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Development
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1. The graphic display for a distillation column in a refining train would BESTfit in the
HMI Display hierarchy at which level?
A. Plant
B. Area
C. Group
D . Loop
2. When developing HMI screens it is recommended that the quantity of items an
operator has to remember is less than:
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A.1.
B. 3.
C. 7.
D.20.
3. The average person cannot respond to signals more frequent than one every:
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A.
B.
C.
D.
30 milliseconds.
80 milliseconds.
300 milliseconds.
800 milliseconds.
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A.
B.
C.
D.
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5. Which database arranges data in a tabular format and links records by key values?
A.
B.
C.
D.
Hierarchical
Neutralized
Relational
Distributed
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www.isa.orglCAP
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Development
7. In a typical PLC timer, what does the function of the preset value determine?
A.
B.
C.
D.
The
The
The
The
Intrusion detection
Public key encryption
Password authentication
Firewall
www.isa.orgiCAP
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Development
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C. Group
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Reference:
Lukas. Distributed Control Systems, Van Nostrand Reinhold, 1986.
2.
C. 7
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Studies show that people can remember approximately seven new things for about 20
seconds. This is called short term memory. After 20 seconds, people will have lost the
information if they cannot quickly store it in long-term memory.
Reference:
Weinschenk. Gill Design Essentials, Wiley Computer Publishing. 1997.
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3.
C. 300 milliseconds
The average person cannot process signals more frequent than one every 300 ms, or
about three signals per second. Therefore, for reliable regulation of events that are faster
than three signals per second, a person should not act as the controller.
Reference:
Albert and Coggan. Fundamentals of Industrial Control. ISA, 2004.
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Storing data using an efficient data compression algorithm is the correct answer.
Storing high frequency process data online for a minimum of 10 years does not suggest
any data-comparison techniques. Storing discrete values efficiently by combining bits
www .isa.orgiCAP
24
Development
into hexadecimal values could result in lost time-stamp data. Using interpolate
historical values to align time stamps would corrupt the actual data.
Reference:
Fisher. Batch Control. ISA, 1996.
5. C. Relational
A relational database arranges information in a tabular format with each table, or
"relation," contributing data that describes a particular type of object. All connections
between tables are based on shared key values. In a hierarchical database, information
is maintained in a tree structure that emphasizes relationships between superior and
subordinate items. In a neutralized database, predefined links connect many leaves in a
tree. Distribution is not a standard database model.
Reference:
Fisher. Batch Control. ISA, 1996.
25
Development
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electronic lighting ballasts all include switching power supplies, which is known to
produce noise in the system due to the high switching rate.
Reference:
Polka. Motors and Drives. ISA, 2003.
-)
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9. D. Firewall
Firewalls enforce access control policies using mechanisms that either block or permit
certain types of traffic, thus regulating the flow of information. Public key encryption,
password authentication, and intrusion detection are security techniques that block
access to users.
)
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Reference:
ISA TR99.00.01 - 2004 - Security Technologies for Manufacturing and Control Systems.
ISA,2004.
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10. D. D
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Reference:
Hughes. Programmable Controllers. ISA, 2001.
11. D. Process flow diagrams
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Process flow diagrams depict the flow of material through a plant, the major
equipment, and their capacities. These diagrams make it very easy to visualize the plant
asa whole.
Piping & Instrumentation diagrams are derived from PFDs and typically have too much
detail to visualize the entire plant. Plant layout drawings provide a visual
representation of the physical locations of buildings, major structures, and major
equipment, much like a map. System architecture diagrams show the interconnection of
all the major control system components. They do not provide much information on
how the plant works.
Reference:
Liptak. Instrument Engineers' Handbook: Volume 3 (3rd Edition) Process Software and
Digital Networks. CRC Press, 2002.
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www.i sa.org/CAP
26
Deployment
PERFORMANCE DOMAIN V
DEPLOYMENT
Field installation and checkout and startup of the systems
Task 1: Perform receipt verification of all field devices by comparing vendor
records against design specifications in order to ensure that devices are as
specified.
Task 2: Perform physical inspection of installed equipment against construction
drawings in order to ensure installation in accordance with design drawings and
specifications.
Task 3: Install configuration and programs by loading them into the target
devices in order to prepare for testing.
Task 4: Solve unforeseen problems identified during
trou bleshooting skills in order to correct deficiencies.
installation
using
27
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Deployment
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A. Procurement.
B. Inspection.
C. Takeoff.
D. Requisition.
2. A diagram that shows all electrical devices and wiring details specific to a particular
physical location is commonly referred to as a(n)
diagram.
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A. Arrangement
B. Termination
C. Loop
D. Schematic
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n zoo
4. Considering a 60Hz power source, at what speed does a 4-pole synchronous motor
run?
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A.1200RPM
B. 1800RPM
C. 2400RPM
D.3600RPM
5. When a large automation project makes significant changes to plant operations, it is
BEST to perform operator training:
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A.
B.
C.
D.
Six months prior to the startup phase, during control system development.
After acceptance testing and prior to the startup phase.
During the startup phase after water batching.
After the startup phase is complete and the process has stabilized.
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www.isa.orglCAP
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Deployment
6. If the distance in a sheet line from the thickness gauge to the manipulated diebolt
actuators is 200 meters and the speed is 4 meters per second, then the dead time from
the transportation delay for thickness control is
seconds.
A. 200
B. SO
C.S
D.0.02
Rate time
Reset time
Gain
Filter time
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Deployment
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A material takeoff is the process of analyzing the drawings and determining all the
materials required to accomplish the design. The material takeoff is then used to create
a Bill of Materials. Inspection does not aid in creating a Bill of Material. Procurement
and requisition are activities that occur after the Bill of Materials is complete.
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Reference:
Whitt. Successful Instrument and Control System Design. ISA, 2004.
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2.
B. Termination
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The termination diagram's purpose is to show all electrical devices and wiring details
specific to a particular physical location. Arrangement drawings show the dimensional
mounting arrangement of all devices specific to a particular physical location and to
prove installation specifics and Bill of Material. A loop diagram's purpose is to use the
process function as the focal point and show all wiring and devices required to
accommodate that function. A scheme diagram shows electrical devices and wiring
details required for correct operation regardless of physical location or wiring methods.
Reference:
Whitt. Successful Instrument and Control System Design. ISA, 2004.
3. C. 20
Equipment in a pipeline, such as static mixers, split up or stratify streams that need
some distance to recombine to reduce the noise in the measurement. 20 pipe diameters
will provide enough mixing in most cases for turbulent flow and liquid mixing. 200
pipe diameters will introduce too much transportation delay. 2 pipe diameters and 0.2
pipe diameters are insufficient to recombine streams.
)
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Reference:
Blevins, et aI. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit, ISA. 2003.
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www.isa.orglCAP
30
Deployment
4. B. 1800 RPM
2 x frequency x 60
# Poles
For a 60 Hz, 4 pole motor = 2 x 60 x 60 = 1800 RPM
4
Therefore, 1800 RPM is the correct response.
Synchronous spend in RPM
Reference:
Webb. Industrial Control Electronics, 2nd Edition. Prentice Hall, 1993.
6. B. 50
The time it takes the sheet to go from the diebolt actuators, which are the manipulated
variable, to the thickness gauge that transverses the sheet to provide the controlled
variable (sheet thickness profile across the sheet), is the transportation delay.
50 seconds: Distance / velocity (200 meters/ 4 meters per sec) is the transportation
delay
Reference:
McMillan. Good Tuning: A Pocket Guide. ISA, 2000.
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA, 2003.
www .isa.org/CAP
31
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Deployment
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7. B. Closed loop.
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Reference:
McMillan. Good Tuning: A Pocket Guide. ISA, 2000.
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8.
A. Rate time
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Reference:
McMillan. Good Tuning: A Pocket Guide. ISA, 2000.
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www .isa.orglCAP
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PERFORMANCE DOMAIN VI
OPERATIONS AND MAINTENANCE
Long term support of the system
Task 1: Verify system performance and records periodically using
established procedures in order to ensure compliance with standards,
regulations, and best practices.
Task 2: Provide technical support for facility personnel by applying system
expertise in order to maximize system availability.
Task 3: Perform training needs analysis periodically for facility personnel
using skill assessments in order to establish objectives for the training
program.
Task 4: Provide training for facility personnel by addressing identified
objectives in order to ensure the skill level of personnel is adequate for the
technology and products used in the system.
Task 5: Monitor performance using software and hardware diagnostic tools
in order to support early detection of potential problems.
Task 6: Perform periodic inspections and tests in accordance with written
standards and procedures in order to verify system or component
performance against requirements.
Task 7: Perform continuous improvement by working with facility
personnel in order to increase capacity, reliability, and/or efficiency.
...,
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Operations and Maintenance
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B. Resistance.
C. Induction.
D. Semiconduction.
2. One of your training objectives is to teach the operator to successfully react to a
process upset. The MOST effective method to achieve that goal is to:
A. Review the control system logic with the operator.
B. Provide a copy of the standard operating procedure manual.
C. Provide a hands-on session in a virtual plant environment.
D. Review the system alarm list.
3. If diagnostic software flags a controller as having high process variability when its
output is hitting a low limit, the MOST probable cause is a(n):
A. Zero shift in the measurement.
B. Noisy measurement.
C. Nonlinear control valve.
D. Over-sized control valve.
4. Which of the following MUST be performed to reveal a normally undetected fault in
a safety system?
A. Proven in use
B. Proof test
C. System software test
D. System validation
Expert system.
Operator's sweet spot.
Process flow diagram.
Review of cost sheets and historian data with operations.
www.isa.org/CAP
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Operations a nd Maintenance
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C. Induction.
Most AC motors work on the principle of induction. The motor consists of a rotor
(rotating portion) with a laminated iron core containing copper bars in the slots. In
addition, the motor contains stator field windings (stationary portion). When AC
current is applied to the stator a current is induced in the rotor producing a rotor field
polarity that opposes the stator field. Capacitors may be used for starting single-phase
motors, but this does not apply to the operational basics of the motor, as capacitance
refers to the storage of energy (not a function of a motor). A motor does include
resistance, but the operation of the motor rotation is not due to its resistance. Basic
motor operation has no relation to semiconduction.
Reference:
Tomal. Electronic Troubleshooting. McGraw-Hill, 1998.
Providing a hands-on session in a virtual plant environment is the ideal method. Handon sessions will demonstrate to the operator what they might see during normal
conditions as well as during upset conditions. Reviewing the control system logic with
the operator would be useful if the operators have a technical background and
understand logic. However, this may not be the case. Standard Operating Procedures
do not familiarize the operator with the control system interface to the point that
he/ she will be able to recognize problems. Reviewing the system alarm list is also not a
solution. The alarm list tells the operator what is wrong; however, one problem can
raise a number of individual alarms. An operator needs to understand how to correlate
multiple alarms to quickly identify the cause.
Reference:
Blevins, et aI. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA, 2003.
www.isa.org/CAP
37
)
Operations and Maintenance
)
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Reference:
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. lSA, 2003.
)
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4. B. Proof Test
A proof test on a system may reveal faults that would otherwise not be mentioned by
internal diagnostic measures and is therefore correct. Proven in use is an assessment on
suitability for use and not related to fault detection. A system software test is only
related to software and not system faults. System validation is performed to test to
requirements and specifications and may not reveal faults which have not been refined
by the requirements.
Reference:
lEC. IEC 61511-1. 2002,
Tomal. Electronic Troubleshooting, McGraw-Hill. 1998.
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www. isa.org/CAP
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The peak performance is needed to determine the gaps in an opportunity sizing. Cost
sheets show the best periods of operation and data historians explain the conditions and
relationships. However, these must be reviewed in the operations to rule out extraneous
information and explain special conditions. The operator's "sweet spot" is most often
based on what makes the job easiest. Process flow diagrams depict how it should be
and not the way it is and may be based on sub-optimum design criteria. Expert systems
are too fuzzy and tend to reflect a narrow and prejudiced knowledge base.
Reference:
Blevins, et al. Advanced Control Unleashed: Plant Performance Management for
Optimum Benefit. ISA, 2003.
www .isa.orglCAP
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Feasibility Study
Definition
System Design
Development
Deployment
Operation and Maintenance
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Resources
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Domain
1 2 3 4 5 6
X X
X X
X
X
X X
X X X X X X
X X X X
X X X X X X
X X X X X X
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www.isa.org/CAP
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Resources
rtJ
Domain
1 2 3 4 5 6
X
X
X
X
X X
X X
X
X
X X
X X
X
X
X X X X X X
X
X X X X
X X
X X
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Resources
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Preventive Maintenance
(ISA, 2004) - www.i sa.org/preventivemaintenance
Principles and Practices of Automatic Process Control, 2 M Edition
(Wiley, ]997) - www.wiley.com
Programming Industrial Control Systems Using IEC 1J 31-3
(lEE Publishing, ]998) - www.iee.org.uk
Quality Management, 3ra Edition
(McGraw-Hili/Irwin, 1995) - books.mcgraw-hill.com
S88 Implementation Guide
(McGraw-Hili, 1998) - books.mcgraw-hill.com
Safety Integrity Level Selection - Systematic Methods Including Layer
of Protection Analysis
(ISA, 2002) - www.isa.org/safetyintegrity
Safety Instrumented Systems: Design, Analysis, and Justification,
2nd Edition
(ISA, 1998) - www.isa.or~/SafetvInstrumentedSvstems
Successful Instrument and Control System Design
(ISA, 2004) - www.isa.org/iandcdesignCD
The New Rational Manager
(Kepner-Tregoe, 1997) - www.kepner-tregoe.com
Troubleshooting: A Technician's Guide
(ISA, 2000) - www.isa.org/troubleshoot
Understanding Distributed Processor Systems for Control
(ISA, 1999) - www.isa.org/distributedcontrol
ISA-5.1-1984 (1992) Instrumentation Symbols and Identification
(ISA, 1992) - www.isa.org/isa511984
ANSIIISA-84.0 1-1996 - Application of Safety Instrumented Systems for
the Process Industries
(lSA, 1996) - www .isa.or~/isa840 1996
ANSIIISA-88.0 1-1995 - Batch Control Part I: Models and Terminology
(ISA, 1995) - www.isa.org/isa880] 1995
ANSIIISA-88.00.03-2003 - Batch Control Part 3: General and Site
Recipe Models and Representation
(ISA, 2003) - www.isa.on!lisa8800032003
ANSIIISA-95.00.0 1-2000 - Enterprise-Control System Integration Part
I: Models and Terminology
(lSA, 2000) - www.isa.on!lisa9500012ooo
ISA-TR99.00.01-2004 - Security Technologies for Manufacturing and
Control Systems
(lSA, 2004) - www.isa.orvisatr99000]2004
www.isa.org/CAP
Domain
1 2 3 4 5 6
X
X
X X
X
X X
X
X X
X X
X X X X X
X
X
X
X X
X
X
X
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