CAP Study Guide.pdf

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~ Certified Automation Professional" (CAP®)

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Setting the Standard for Automation

The CAIJ® Study Guide is designed to provide a review of key content areas ...

(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

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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.

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Certified Automation Professionaie Study Guide - Version 4.1 Revision Date: August 2007 ,

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©ISA -2007

All rights reserved. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), without prior written permission of the Publisher: ISA 67 Alexander Drive PO Box 12277 Research Triangle Park, North Carolina 27709 U.S.A. http;lfwww·isa.org Library of Congress Cataloging-in-Publication Data Certified Automation Professionals' (CAP®) program study guide. p.cm. ISBN 1-55617-888-3 1. Automatic control-Study and teaching. 2. Technicians in industry--Certification. I. ISA--The Instrumentation, Systems and Automation Society. TJ213.C46 2004 629.8--dc22 2004011284

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CAp® Study Guide

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Table of Contents

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Introduction

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Domain 1: Feasibility Study- identify, scope, and justify the automation project

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Domain 2: Definition- identify and analyze customer requirements

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Domain 3: System Design- design, specify, and procure the hardware/ software used in the control and information system

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Domain 4: Development- software development and coding

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Domain 5: Deployment- field installation, checkout, and startup of the systems

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Domain 6: Operation and Maintenance - long term support of the system

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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.

CAP PROGRAM OVERVIEW The development of a valid examination for the CAP certification process began with a clear and concise definition of the knowledge, skills, and abilities needed for competent job performance. Using interviews,

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surveys, observation, and group discussions, ISA worked with automation professionals to delineate critical job components. The knowledge and skill bases for the questions on the examination were derived from the actual practice of the automation professionals as outlined in the 2004 CAP Role Delineation Study. CASTLE followed the NOCA and ANSI standards for test development. The NOCA standards are published in: National Commission for Certifying Agencies (2002). Standards for the Accreditation of Certification Programs. Washington, D.C.: National Organization for Competency Assurance. The American National Standards Institute (ANSI) administers a program for the accreditation of personnel certification programs, using ISO jlEC Standard 17024.

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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information needed for the CAP to perform his or her role effectively. To ensure that the most stringent test development requirements were employed during the development of CAP, ISA contracted with CASTLE Worldwide, Inc., a full-service testing company providing licensure, certification, and specialty examinations.

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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The following are acceptable work experience and education requirements: I. If you hold a 4 Year Technical Degree:

o Four-year academic degree from an accredited educational institution in a technical or technology field including engineering, chemistry, physics, math, etc. (J

Related work experience. Related experience means a minimum of five years of work in the automation field. One (1) year of work experience means 1,500 hours of active employment. A cumulative total of 7,500hours of documented work experience is required during the five year period prior to your application date.

n. If you hold a 2 Year Technical Degree or do not have a degree:

l:l Related work experience. Related experience means a minimum of ten (10) years of work in the automation field. One (1) year of work experience means 1,500 hours of active employment. A cumulative total of 15,000 hours of documented work experience is required during the ten (10) year period prior to your application date. A two year associate degree in automation or a related field from an accredited institution may be used to satisfy two years of the ten year work requirement.

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Evidence of responsible charge position; Two (2) work related references should be submitted that demonstrates that the applicant has had at least two (2) years experience in automation in a position of responsible charge. Each reference should be completed and signed by a former supervisor or someone who is in a position to attest to the applicant's responsibilities. At least one of the references must be signed by a current or former supervisor. See below for a definition of "responsible charge."

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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in the form of a statement signed by a co-worker from that period of employment and notarized by a notary public. A full explanation of why the employer is not verifying the period of employment must be provided. Full contact information, i.e., name, address and telephone number, must be provided for all responsible parties who act to confirm employment verification. Self employed applicants should complete the Verification of Employment form to document the required work experience and include a notarized letter from at least three (3) current customers (customers during the eligibility period), including full contact information for customers. Position of Responsible Charge For applicants who do not meet the four-year technical degree requirement, two verifications must accompany your application that document that you have held a position of responsible charge in the automation field for at least two (2) years. One of the references must be from your direct supervisor. Responsible charge relates to the span or degree of control an automation professional has to maintain while exercising independent control and direction of professional automation work, and to the level of decisions being made. Responsible charge does not refer to management control or administrative functions such as

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accounting, labor relations, or marketing. The span of control necessary to be considered in a position of responsible charge includes: • Personally makes critical automation project decisions, or reviews and approves proposed decisions prior to implementation, including consideration of alternatives. OR

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Judges the quality of other technical specialists and the validity and applicability of their recommendations before such recommendations are incorporated in the work.

No documents will be returned to applicants. Please keep a copy of your application for your records.

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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

from work experience. A year is defined as 1,500 hours of active employment. You must have worked in the automation field for 3,000 total hours during the 3 year renewal period. • A minimum of 45 hours of continuing education or professional development activity in an automation or job-related field. An hour is defined as a minimum of 50 minutes. Continuing education units (CEUs) from an authorized provider are acceptable. One CEU equals 10 PDPs. Applicants without required documentation will be notified to submit the necessary verification. If the applicant does not respond within three (3) months, then the application is considered abandoned. Applicant will have to submit a new application and the renewal fee again to apply for renewal. Record Retention Policy All documentation received from CAP applicants who are not eligible for certification will be retained for one year after the application is received.

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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Candidates will have four hours to complete the examination. The following tables indicate the percentage of questions appearing on the exam as they relate to each of the CAP domains and technical topic categories to ensure broad coverage of information which is especially helpful for those preparing for the CAP exam. Domains 1 2 3 4

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Feasibility Study Definition System Design Development Deployment Operation and Maintenance

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12% 15% 25% 22% 15% 11%

Technical Topic Categories % of Questions 1 2

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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 %

The examination is closed book. No reference material of any kind may be brought in the exam room.

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TAKING THE EXAM For information on taking the CAP exam, visit www.isa.orgiCAP, email ISA at [email protected], or call Customer Service at (919) 549-8411. The examination is offered in an electronic format, or in the paper/ pencil format for private exam sites. ISA may administer the CAP exam atspecial events and these may be found on the ISA Network. All candidates will have four hours to complete the exam. Electronic exams are available during three testing windows as shown in the table below. For details on applying for electronic testing go to www.isa.orglexamschedule. 2008 Exam Testing Windows

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

If the number of candidates for a private exam site or a special event administration of CAP falls below the minimum number preestablished for the session, ISA reserves the right to cancel the session and reschedule the affected examinees as quickly as possible. If an exam site must be cancelled because of a weather condition or insurmountable problems in regard to exam availability, test room availability, or proctor availability, ISA will contact the candidates as

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quickly as possible and arrange a replacement exam date. Although rare, the potential exists for a cancellation to occur as late as the actual day of the exam. Candidates will not be admitted to the examination once it has begun. All candidates should bring their confirmation letter and a valid photo identification with signature to the examination site. Acceptable forms of identification include driver's licenses, passports, and governrnentissued identification cards. Unacceptable forms of identification include gym memberships, warehouse memberships, school identification cards, and identification with signature only. In addition, candidates who are taking the paper/pencil exam format should bring at least two No.2 pencils, a soft eraser suitable for cleanly erasing incorrect and stray markings, and a self-powered or battery-operated non-programmable calculator. Electronic candidates will be provided with a calculator on the computer at the test center.

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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.

Please make all checks payable to ISA. Your canceled check is your proof of payment. If you require a receipt you must contact ISA. Fees are due in advance and ARE NOT REFUNDABLE. It is the responsibility of the applicant to thoroughly review the requirements for the examination and apply only if he or she is qualified. No refunds will be made for applicants who do not appear for testing on the scheduled date.

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 [email protected] 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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Section B: Job and Industry Classification Indicate your primary job function and the industry in which you currently work. Section C: Certification Exam Selection Information Mark the appropriate box if you wish to test electronically. For private exam sites or special administrations, specify the date, city, and state where you will take the test. Section D: Employment Summary Complete a record of employment that fully covers the experience requirement to sit for the examination. Section D must be completed in addition to any other documentation submitted to verify employment. Section E: Education/fraining Complete a record of education and training that fully covers the education requirement to sit for the examination. Official transcripts must be submitted as documentation to verify educational degrees. Certificates do not serve as verification of an apprenticeship or training. This experience must be verified by signed documentation. Section F: Verification of Employment Verification of Employment forms must be completed and signed for all work experience claimed as qualification for examination. All

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documentation must be provided in English. Faxed verification is not accepted. The original signature must be provided on this form. You should also use this form to document the two references required to meet the responsible charge eligibility if you do not have a four year technical degree. Section G: Verification of Employment in Position of Responsible Charge Verification of Employment in Position of Responsible Charge forms must be completed by your current and/ or former supervisor(s) if you are documenting ten (10) years of automation experience as eligibility criteria to sit for the CAP exam. Two references should be submitted that documents that at least two (2) years of the ten (10) years experience must be in a position of responsible charge. Section H: Compliance with Certification Criteria and Qualifications Read carefully and sign the compliance agreement. Section I: Fees All applications must be accompanied by full payment of the required fees. No exceptions will be granted. Section J: Submitting Materials Mail application and fee to ISA. Incomplete or incorrectly completed applications may be returned to an

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applicant. It is the responsibility of the CAP applicant to promptly notify ISA in writing of any changes in his/her name or address. Notification for admission to the examination, test results, and renewal of certification depends on accurate information.

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If mailing with a check payment or

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through regular postal delivery, send all materials to:

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ISA CAP Program P.O. Box 3561 Durham, NC 27702

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If mailing with credit card payment

or by overnight service, send all materials to: ISA CAP Program 67 Alexander Drive Research Triangle Park, NC 27709

applications completed in pencil are not accepted. Certification Status

Each application will be reviewed for the necessary requirements. If there are deficiencies, candidates will receive a letter outlining what documentation is still required. Electronic exam candidates will receive an eligibility letter with instructions on how to register for an exam date. For private exam sites or special exam administrations, applicants will receive a confirmation letter that will include the time, location, and a map, when available, to the testing site. Results for each paper/pencil exam applicant will be mailed within thirty (30) days after the examination date. Electronic candidates will receive immediate results at the testing center.

Materials sent to any other address will be returned. Fax, e-mail, and photocopied applications, or

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DUE PROCESS PROCEDURES If an applicant feels he/she was wrongly denied certification, original or renewal, from the CAP program, then he/she has the right to appeal. I.

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.

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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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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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THE ISA CODE OF ETHICS Preamble As engineers, scientists, educators, technicians, sales representatives, and executives in an important and learned profession; and in order to safeguard public welfare; and to establish and maintain a high standard of integrity and practice; and as members of ISA, we hold to these Articles: Article I Members shall hold paramount the safety, health and welfare of the public in the performance of their duties, and shall notify their employer or client and such other authority as may be appropriate where such obligations are abused. Members shall hold in confidence facts, data and information obtained in a professional capacity, unless the release thereof is authorized by their employer or client, and shall not engage in fraudulent or dishonest business or professional practices. ArticleD Members shall perform services only in areas in which they are qualified by education or experience, and shall endeavor to maintain their professional skills at the state of the art. Members shall practice their profession in a manner which will uphold public appreciation of the services they render.

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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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associations and professional registrations without exaggeration and in accordance with the laws of the locations in which they practice.

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Article VI

Members shall pledge themselves to live and work according to the laws of man and to the highest standards of professional conduct, using the ir knowledge and skills to the benefit of all mankind.

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Why Should You Join ISA?

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Founded in 1945, ISA (www.isa.org) is a leading, global, nonprofit organization that is setting the standard for automation by helping over 30,000 worldwide members and other professionals solve difficult technical problems, while enhancing their leadership and personal career capabilities. Based in Research Triangle Park, North Carolina, ISA develops standards; certifies industry professionals; provides education and training; publishes books and technical articles; and hosts the largest conference and exhibition for automation professionals in the Western Hemisphere.

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Here are some of the benefits you enjoy as an ISA Member: I. Stay current within your field by reading your free InTec11 magazine every month.

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

Task 1: Define the preliminary scope through currently established work practices in order to meet the business need. Task 2: Determine the degree of automation required through cost/benefit analysis in order to meet the business need. Task 3: Develop a preliminary automation strategy that matches the degree of automation required by considering an array of options and selecting the most reasonable option in order to prepare feasibility estimates. Task 4: Conduct technical studies for the preliminary automation strategy by gathering data and conducting an appropriate analysis relative to requirements in order to define development needs and risks. Task 5: Perform a justification analysis by generating a feasibility cost estimate and using an accepted financial model to determine project viability. Task 6: Create a conceptual summary document by reporting preliminary decisions and assumptions in order to facilitate "gd'/"no go" decision making.

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1. Gathering requirements is critical to the success of an automation project because they:

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A. Establish the design and engineering schedule. B. Provide a basis for performing calculations. C. Define the purpose, scope, and objectives. D. Determine funding and buy-in from stakeholders.

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2. Which of the following control strategies is used to measure disturbances and compensate for them before they cause the controlled variable to deviate from the setpoint?

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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) ,-

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---.t

t----r---+ C( s)

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A.

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B.

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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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ANSWER KEY - DOMAIN I

1. C. Define the purpose, scope, and objectives.

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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

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A. Feedforward B. Feedback C. Cascade D.Openloop

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The objective of feedforward control is to measure disturbances and compensate for them before the controlled variable deviates from setpoint. Feedback control can compensate for a disturbance only after the control variable has deviated from setpoint. Cascade is a form of feedback control. Open loop is not a control strategy.

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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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PERFORMANCE DOMAIN II DEFINITION ldentifiJ customer requirements and complete high-leoel analusi« of tire best way to meet those requirements

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Task 1: Determine operational strategies through discussion with key stakeholders and using appropriate documentation in order to create and communicate design requirements.

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Task 2: Analyze alternative technical solutions by conducting detailed studies in order to define the final automation strategy. Task 3: Establish detailed requirements and data including network architecture, communication concepts, safety concepts, standards, vendor preferences, instrument and equipment data sheets, reporting and information needs, and security architecture through established practices in order to form the basis of the design. Task 4: Generate a project cost estimate by gathering cost information in order to determine continued project viability.

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Task 5: Summarize project requirements by creating a basis-of-design document and a user-requirements document in order to launch the design phase.

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Definition

1. Which of the following is NOT a benefit of using an agenda for discussions? A. B. C. D.

An An An An

agenda assures meeting objectives. agenda keeps discussion on track. agenda helps manage time. agenda allows everyone equal participation.

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.

Overhead pressure controller. Linear reflux valve. Reflux controller. Reboiler stream ratio controller.

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.

Real-time optimization with a detailed process model Tactical schedulers w ith business economics Linear programs with detailed process economics Model predictive controls with a constraint pusher

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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6. According to NFPA Electrical Standards for Industrial Machinery, which of the following actions in NOT acceptable for emergency operations? A. Using a locally supplied disconnect B. Using an emergency stop to override all other functions and operations with all modes C. Using an emergency switch off initiated by a single human action D. Resetting an emergency stop circuit to initiate a restart 7. Which of the following contract types places the PRIMARY risk with the supplier?

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A. B. C. D.

Cost plus Fixed price Time and material Unit price

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Definition

ANSWER KEY - DOMAIN II

1. D.

An agenda allows everyone equal participation

An agenda does not enforce an individual's participation.

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.

3. B. Multivariable statistical process controls Artificial Neural Networks excel at modeling nonlinear relationships for a relatively large unknown number of inputs. However, the inputs cannot be correlated and the training data must cover the whole region. An ANN cannot be used to extrapolate values outside the test region and doesn't handle large lags well. The multivariate statistical-process control excels at modeling unknown linear relationships for a large number of inputs that could be correlated. Step response models excel at linear relationships for a small to moderate number of uncorrelated inputs where dynamics are important. Step response models are used for linear dynamic on-line property estimates. First principle models require known equations and parameters that use process principles and material and energy balances. Reference: Blevins, et al. Advanced Control Unleashed: Plant Performance Management for Optimum Benefit. ISA, 2003. www.isa.org/CAP

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4. A. Real-time optimization with a detailed process model.

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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.

6. D. Resetting an emergency stop circuit to initiate a restart The reset of an emergency stop circuit will not initiate a restart; therefore, the answer is not an acceptable emergency operation and is the correct answer. Emergency stop to override all other functions and operations with all modes is an acceptable emergency operation, per NFPA 79 - 9.2.5.4.11. Emergency switching off initiated by a single human action is an acceptable emergency operation, per NFPA 79 - 9.2.5.4.1. Using a locally supplied disconnect is an acceptable emergency operation, per NFPA10.7.5.1.

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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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PERFORMANCE DOMAIN III SYSTEM DESIGN

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Design, specifi], and procure the hardtoare / software used in the system

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Task 1: Perform safety and/ or hazard analyses, security analyses, and regulatory compliance assessments by identifying key issues and risks in order to comply with applicable standards, policies, and regulations.

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Task 2: Establish standards, templates, and guidelines as applied to the automation system using the information gathered in the definition stage and considering human-factor effects in order to satisfy customer design criteria and preferences.

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Task 3: Create detailed equipment specifications and instrument data sheets based on vendor selection criteria, characteristics and conditions of the physical environment, regulations, and performance requirements in order to purchase equipment and support system design and development.

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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 5: Select the physical communication media, network architecture, and protocols based on data requirements in order to complete system design and support system development. Task 6: Develop a functional description of the automation solution (e.g., control scheme, alarms, HMI, reports) using rules established in the definition stage in order to guide development and programming.

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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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1. Which of the following standards applies to the development of embedded software for a SIL 3 certified safety system? A. ANSE/ISA 584 B. IEC 61511 C. rsc 61508 D. 20 CFR Part 11 2. Which of the following protection techniques is acceptable for equipment located in a Class I, Division 1 area?

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A. B. C. D.

Explosion-proof apparatus and nonincendive equipment Explosion-proof apparatus and intrinsic safety Dust ignition-proof and nonincendive equipment Hermetically sealed and intrinsic safety

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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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A. B. C. D.

Black, red, blue, yellow. Black, red, orange, yellow. Brown, red, orange, yellow. Brown, black, white, red.

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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

7. An application includes a VFD that implements a V /Hz method of torque control while maintaining a fixed V 1Hz ratio. The motor has a nameplate rating of 460 volts and 60Hz. If the drive is operating at 30Hz, what percent of rated torque will the motor MOST likely develop? A.25% B. 50% e. 100% D.200% 8. To measure the level of a liquid with a dielectric constant greater than 2 in a horizontal vessel with changing composition and temperature, the device with BEST reproducibility is a: A. Radar level detector. B. Ultrasonic level detector. e. Capacitance level detector. D. Differential pressure transmitter.

9. To minimize electrical interference when AC power and DC signal wiring meet in a control panel, it is BEST to: A. Use a different size wire.

B. Cross the wires at 90 degrees. Run the wires parallel to each other. D. Twist the AC wires around the DC wires.

e.

10. Using Modbus, what is the MAXIMUM level of precision available? A. 8-bits B. 16-bits e. 24-bits D. 32-bits

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11. How is PID defined in the phrase liPID control loop"? A. Proportional Instrument Device

B. Piping Instrumentation Diagram C. Percentage Integration Delta D. Proportional Integral Derivative

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12. P&ID is an acronym for which of the following? A. B. C. D.

Process and Instruction Document Process and Instrument Diagram Piping and Instrument Diagram Piping and Installation Drawing

13. Which fuse has the quickest response to overcurrents? A. Single-element B. Dual-element C. Time-delay D. Dual-element time-delay

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System Design

ANSWER KEY DOMAIN m

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.

2. B. Explosion-proof apparatus and intrinsic safety Hazardous location protection techniques are defined by NEC 500.7 (NEC 2002 Code). The protection techniques are permitted as follows: Explosion proof apparatus - Class I, Divl or 2 Intrinsic safety Class I, Div 1 or2; Class IT Div 1 or 2; or Class III, Div 1 or 2 Non-incendive equipment - Class I, Div 2; Class IT, Div 2; or Class ill, Div 1 or 2 (Does NOT Include Class 1, Div 1) Dust ignition proof Class II, Di 1 or 2 (Does NOT include Class I, Div 1) Class I, Div 2; Class II, Div 2; Class III, Div 1 or 2 Hermetically sealed (Does NOT include Class I, Div 1) Reference: Earley. NEC 2002 Handbook. NFPA, 2002.

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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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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5. A. Black, red, blue, yellow

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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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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.

A. Radar level detector

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.

9. B. Cross the wires at 90 degrees Crossing the wires at 90 degrees will minimize the exposure of the wire to each other and therefore minimize the effects of interface. Using a different size wire will have no effect on the electrical interference. Running the wires parallel to each other will increase the exposure of the wires to each other and increase the effects of interference. Twisting the AC wires around the DC wires will also increase the effects of interference. Reference: Hughes. Programmable Controllers. ISA, 2001.

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.

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11. D. Proportional Integral Derivative

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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12. C. Piping and Instrument Diagram

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P & ID is a widely used acronym for Piping and Instrument Diagram. Reference: Fleming. 588 Implementation Guide. McGraw-Hill, 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

Task 1: Develop Human Machine Interface (HMI) in accordance with the design documents in order to meet the functional requirements. Task 2: Develop database and reporting functions in accordance with the design documents in order to meet the functional requirements. Task 3: Develop control configuration or programming in accordance with the design documents in order to meet the functional requirements. Task 4: Implement data transfer methodology that maximizes throughput and ensures data integrity using communication protocols and specifications in order to assure efficiency and reliability. Task 5: Implement security methodology in accordance with stakeholder requirements in order to mitigate loss and risk. Task 6: Review configuration and programming using defined practices in order to establish compliance with functional requirements. Task 7: Test the automation system using the test plan in order to determine compliance with functional requirements. Task 8: Assemble all required documentation and user manuals created during the development process in order to transfer essential knowledge to customers and end users.

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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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30 milliseconds. 80 milliseconds. 300 milliseconds. 800 milliseconds.

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Store data using an efficient data compression algorithm. Store high-frequency process data online for a minimum of 10 years. Store discrete values efficiently by combining bits into hexadecimal values. Interpolate historical values to align time stamps.

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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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Development

6. Which PLC programming languages consists of contacts, timers, and counters? A. B. C. D.

Sequential Function Charts (SFC) Ladder Diagram (LD) Function Block Diagram (FBD) Structured Text (ST)

7. In a typical PLC timer, what does the function of the preset value determine? A. B. C. D.

The The The The

resolution of the time base such as 1/10 sec or 1/100 sec length of time before the timer is energized or de-energized length of time the timer has been active on-delay or off-delay setting that determines the reset of the timer

8. Which of the following is NOT a strong source of electrical noise? A. B. C. D.

Variable speed drives Switching power supplies Electronic lighting ballasts Regulated magnetic transformer power supply

9. Which of the following security technologies would BEST protect a manufacturing and control system from file transfer protocol access from outside the network? A. B. C. D.

Intrusion detection Public key encryption Password authentication Firewall

10. A binary number of 1101 has a hexadecimal equivalent of: A.8. B. 13. C. A. D. D. 11. Which set of documents should be reviewed to gain a quick understanding of plant operations? A. B. C. D.

System architecture diagrams Piping and Instrumentation diagrams Plant layout drawing Process flow diagrams

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ANSWER KEY DOMAIN IV 1.

C. Group

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A typical hierarchy is composed of displays at four levels: Plant level - Provides information regarding the entire plant Area level - Provides information on portions of the plant equipment that is related in someway Group level - Provides information for the control loops and data points relating to a single process unit within a plant area Loop level- Provides information that deals with individual control loops, sequences, or data points A distillation column refers to one piece of equipment in the distillation process which will contain several loops. Therefore, it falls into the group-level category.

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Reference: Lukas. Distributed Control Systems, Van Nostrand Reinhold, 1986.

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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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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.

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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

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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.

6. B. Ladder Diagram (LD) The Ladder Diagram Language consists of relay-type logic, timing, counting, and basic math operations. SFC and FBD are graphical languages in a high level structured language. Reference: Lewis. Programming Industrial Central Systems Using me 1131-3. lEE Publishing, 1998.

7. B. The length of time before the timer is energized or de-energized. A timer pre-set is a programming value for the timing function. The resolution of the time base relates to accuracy. The length of time before the timer is energized or deenergized is a timer function. Reference: Bailey and Wright. Practical SCADA for Industry. Newnes, 2003.

8. D. Regulated magnetic transformer power supply A regulated magnetic-transformer power supply is the only choice that does not include power supply switching. Variable speed drives, switching power supplies, and www.isa.orglCAP

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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

D is correct. In hexadecimal, D is the equivalent of 1101 in binary. 8 in hexadecimal is the equivalent of 1000 in binary. 13 is not a hexadecimal format. A in hexadecimal is the equivalent of 1010 in binary.

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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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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

Task 5: Test configuration and programming in accordance with the design documents by executing the test plan in order to verify that the system operates as specified. Task 6: Test communication systems and field devices in accordance with design specifications in order to ensure proper operation. Task 7: Test all safety elements and systems by executing test plans in order to ensure that safety functions operate as designed. Task 8: Test all security features by executing test plans in order to ensure that security functions operate as designed. Task 9: Provide initial training for facility personnel in system operation and maintenance through classroom and hands-on training in order to ensure proper use of the system. Task 10: Execute system-level tests in accordance with the test plan in order to ensure the entire system functions as designed. Task 11: Troubleshoot problems identified during testing using a structured methodology in order to correct system deficiencies. Task 12: Make necessary adjustments using applicable tools and techniques in order to demonstrate system performance and turn the automated system over to operations. www.isa.org/CAP

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1. A Bill of Materials for purchase of cable on a project is created by completing a material:

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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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3. For a rapid and representative pH measurement at the outlet of an inline neutralizer, such as a static mixer, the electrode should be approximately pipe diameters downstream of the outlet. A.0.2 B. 2 C. 20

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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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

7. If an exothermic reactor can runaway in manual, then the temperature controller should be tuned with a(n): A. B. C. D.

Open loop short cut method. Closed loop. Lambda Tuning method. Reaction curve method.

8. An increase in which setting can compensate for a thermoweIllag time? A. B. C. D.

Rate time Reset time Gain Filter time

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ANSWER KEY DOMAIN V 1. C. Take off.

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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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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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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.

5. B. Mter acceptance testing and prior to the startup phase. The best time to train operators is after acceptance testing and prior to startup. Ideally, you want to train the operators after the bulk of the changes have been made, but before they will need to implement the knowledge. This reduces confusion and also reduces the chance that training will be forgotten. Training needs to occur before the startup phase because the operator would have to know something about the process before they could startup the plant. However, if training occurs too early the operator will forget what has been learned before having a chance to apply the knowledge. Reference: Liptak. Instrument Engineers' Handbook - Volume 3 (3rd Edition): Process Software and Digital Networks. ISA, 2002.

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.

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7. B. Closed loop.

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The controller must stay in automatic to prevent a runaway reaction. Closed-loop methods keep the controller in automatic. Normally, the gain is maximized to the point where either the error is small enough or the process starts to show a slight oscillation. It does not imply the ultimate oscillation method. The controller is in manual for open loop, Lambda Tuning, and reaction curve methods.

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Reference: McMillan. Good Tuning: A Pocket Guide. ISA, 2000.

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Thermowell and temperature processes have multiple interacting thermal lags. Rate time cancels a secondary thermal lag that can improve control in a slow temperature process without AID chatter. Reset time adds another lag that further increases the apparent dead time from multiple lags. A large thermowelllag reduces the allowable gain. A process variable filter adds another lag that further increases the apparent dead time from multiple lags.

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Reference: McMillan. Good Tuning: A Pocket Guide. ISA, 2000.

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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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Task 8: Document lessons learned by reviewing the project with all stakeholders in order to improve future projects. Task 9: Maintain licenses, updates, and service contracts for software and equipment by reviewing both internal and external options in order to meet expectations for capability and availability. Task 10: Determine the need for spare parts based on an assessment of installed base and probability of failure in order to maximize system availability and minimize cost.

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Task 11: Provide a system management plan by performing preventive maintenance, implementing backups, and designing recovery plans in order to avoid and recover from system failures. Task 12: Follow a process for authorization and implementation of changes in accordance with established standards or practices in order to safeguard system and documentation integrity.

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1. Most AC motors operate on the principle of: A. Capacitance.

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

5. The peak performance demonstrated in an operating unit should be based on a(n): A. B. C. D.

Expert system. Operator's sweet spot. Process flow diagram. Review of cost sheets and historian data with operations.

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6. To simultaneously optimize an interacting dead-time dominant process with multiple constraints, one should use a(n): A. Override PID control. B. Model predictive control. C. Decoupled PID controL D. Advisory controL

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ANSWER KEY DOMAIN VI 1.

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.

2. C. Provide a hands-on session in a virtual plant environment.

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.

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3. D. Over-sized control valve Controller output successively hits its low limit and shores a sawtooth oscillation. An oversized control valve will operate next to the seat where the friction and stick-slip is greatest. A noisy measurement increases high-frequency variability but does not necessarily cause a controller output to hit its limit. A nonlinear valve may require detuning but does not necessarily cause a controller output to hit its limit. Zero shift, or bias errors, exists to some degree in all measurements and results in running at a setpoint that is shifted. However, is does not cause a controller output to hit its limit unless it is extremely large, which is not as probable as an oversized valve since such large errors are not common and should have been found during calibration checks and process problems.

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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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5. D. Review of cost sheets and historian data with operations.

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.

6. B. Model predictive control.

Model Predictive Control (MPC) excels at dead-time dominance and simultaneous optimization while accounting for future prediction of proximity to constraints. PID controllers are not suitable dead-time dominance. Derivatives cannot be used, but even PID controllers don't do as well as MPCs. Override controllers select a single PID output and are not simultaneous. PID controllers are not suitable. Decoupling is limited in practice to steady state gains and a small number of variables with no optimization built in. Operators cannot handle the interactions, the dead time or provide minute-tominute simultaneous corrections even if they are given the new setpoints. Reference: Blevins, et al. Advanced Control Unleashed: Plant Performance Management for Optimum Benefit. ISA, 2003.

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ISA Resources for the Certified Automation Professionals' (CAp®) Program

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Resource & Domain Matching A list of possible CAP book resources is provided below. The publisher of the book is noted after the title. ISA also has a variety of training courses that would be helpful in preparing for CAP. Visit www.isa.org/training for a complete list. For more information about the ISA products listed in this chart, go to www.isa.org/books, e-mail ISA at [email protected], call (919) 549-8411, or write to ISA at: 67 Alexander Drive, P.O. Box 12277, Research Triangle Park, NC 27709.

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CAP!> Performance Domains

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Advanced Control Unleashed: Plant Performance Management for Optimum Benefit (ISA, 2003) - www .isa.orz/advancedcontrol Applying Manufacturing Execution Systems (CRC Press, 1997) - www.crcpress .com Applying S88: Batch Control from a User's Perspective (lSA, 2000) - www.isa.org/applyS88 Automation and Control CD or Online Curriculum (Coastal Training Technologies, ISA) - www.isa/distancelearning Batch Control Systems - Design, Application, and Implementation (ISA , 2006) - www.isa.orglbatchcontrol CAP Review Course rsco» (lSA, 2oo5) - www .isa.orglCAPtraining CAP Learning System (lSA, 2006) - www .isa.orglCAPlearn

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Control System Design Guide, 3 Edition (Academic Press, 2004) - www.harcourt-international.com Control System Safety Evaluation and Reliability, 2 na Edition (ISA, 1998) - www.isa.org/safetyevaluation Control System Documentation: Applying Symbols and Identification (lSA, 1993) - www.isa.org/symbolsandlD Electrical Instruments in Hazardous Locations, 41n Edition (ISA, 1998) - www.isa.org/hazardlocations Fieldbuses for Process Control: Engineering, Operation, and Maintenance (lSA, 200 1) - www.isa.orz/fieldbuses Fundamentals of Process Control Theory, 3rd Edition (ISA, 2000) - www.isa.orgltheoryfundamentals Fundamentals of Industrial Control, 2na Edition (ISA, 2004) - www.isa.org.fundamentalcontrol GAMP Good Practice Guide: Validation of Process Control Systems (ISPE, 2003) - www.ispe.org Good Tuning: A Pocket Guide (ISA, 2000) - www.isa.orgltuningpocket Guide to the Automation Body of Knowledge (lSA, 2005) - www.isa.org/autobok Industrial Control Electronics, 2na Edition (Prentice Hall, 1993) - www.prenhall.com Instrument Engineers' Handbook, Volume 3 (3rd Edition): Process Software and Digital Networks (ISA, 2002) - www.isa.org/iehvoI3 Industrial Instrumentation Technician Assessment: Review for Certification, Levels III & IV (lSA , 1994) - www.isa.orz/nicetlflandfv Internetworkin~ with TCP/IP Vol. I: Principles, Protocols, and Architecture, 4' Edition (Prentice Hall, 1995) - www.nrenhall.corn Motors & Drives: A Practical Technology Guide (ISA, 2003) - www.isa.org/motorsanddrives NFPA 79 - Electrical Standard for Industrial Machinery (NFPA, 2002) - www .nfpa.org Practical Project Management - Learning to Manage the Professional (lSA, 200 1) - www .isa.org/projectmanage Practical SCADA for Industry (Newnes, 2003) - www .elsevier.com www.isa.orgiCAP

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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

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