Standards Certification Education & Training Publishing Conferences & Exhibits‘The CAP® 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 | 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. Certified Automation Professional® Study Guide, 24 Edition - Version 1.0 December 2008 ©ISA - 2008 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: International Society of Automation 67 Alexander Drive PO Box 12277 Research Triangle Park, North Carolina 27709 US.A. httpy//[Link] Library of Congress Cataloging-in-Publication Data certified A ISBN 9 1. Autom ion Professional (CAP) study guide. -- 2nd ed. 4394-83-90CAP® Study Guide Table of Contents Introduction. Domain 1: Feasibility Study- identify, scope, and justify the automation project .. Domain 2: Definition- identify and analyze customer requirements... Domain 3: System Design- design, specify, and procure the hardware/ software used in the control and information system ... Domain 4: Development- software development and coding Domain 5: Deployment- field installation, checkout, and startup of the systems . ‘stem Domain 6: Operation and Maintenance - long term support of the s CAP ResourcesWELCOME Thank you for your interest in the ISA Certified Automation Professional® (CAP®) Program. The CAP® program recognizes your experience, knowledge, and education in automation - and provides objective, third-party endorsement of your skills. Certification from ISA demonstrates your 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 acited 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, [Link]/CAP 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/IEC 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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. [Link]/CAP The following are acceptable work experience and education requirement: ‘L If you hold a4 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. O 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 7,500 hours of documented work experience is required during the five year period prior to your application date. IL. If you hold a2 Year Technical Degree or do not have a degree: O 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.Q_ 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 east 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 evidence of work experience including job duties with the initial application. If the application audited, completed Verification of Employment forms for all employers will be required. All forms for audit purposes 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. For employers that may be unavailable to provide first-hand [Link]/CAP verification, a two-party verification of the employment must be provided in the form of a statement signed by a. co-worker from that period of employment and notarized by a notary public. Full contact information, ie. name, address and telephone number, must be provided for all responsible parties who act to confirm employment verification. Self employed applicants and consultants should complete the Verification of Employment form to document the required work experience and include a 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 accounting, labor relations, or marketing.The span of control necessary to be considered ina 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 ‘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. 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 0PDPs 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 ‘[Link]/CAP worked in the automation field for 3,000 total hours during the 3 year renewal period. © Aminimum 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 anew 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 Acomprehensive 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. Candidates will have four hours to complete the examination. The following tables indicate the Vv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 heipful for those preparing for the CAP exam. Domains %% of Questions Feasibility Study Definition System Design Development Deployment Operation and Maintenance ‘Technical Topic Categories % of Questions 1 Basic Continuous Control 2 Discrete, Sequencing, and Manufacturing Control 12% 15% 25% 2% 15% 1% ux Be 3. Advanced Control 9% 4 Reliability, Safety and Flectrical 5. Integration and Software 6 Deployment and Maintenance WorkStructure The examination is closed book. No 13% 2% 16% ux reference material of any kind may be brought in the exam room. TAKING THE EXAM For information on taking the CAP exam, visit [Link]/CAP, email ISA at cap@[Link], or call Customer Service at (919) 549-8411. [Link] The examination is offered in an electronic format, or in the paper/pencil format for private exam sites. ISA may administer the CAP exam at special 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 [Link]/examschedule. 1 March - 30 April | Window 2: | 1 July -31 Ag | Window 3: 1 November ~ 31 | December If the number of candidates for a private exam site or a special event administration of CAP falls below the minimum number pre- established 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 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. Allcandidates 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 government- issued identification cards. Unacceptable forms of identification include gym memberships, warehouse memberships, school identification cards, and identification with signature only. Inaddition, 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. 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 US. 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 [Link]/CAP 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 [Link]/CAP. You may also contact ISA at cap@[Link] or (919) 549- 8411 to request a copy. 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 ISA- related 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. Job and Industry Classification Indicate your primary job function and the industry in which you currently work. vi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 exam. Employment Summary ‘Complete a record of employment that fully covers the experience requirement to sit for the examination. Section D must be completed with a description of job duties in order to process the application. Education/Training Complete a record of education and training that fully covers the education requirement to sit for the examination on the initial application. Official transcripts must ‘be submitted as documentation to verify educational degrees if the application is audited. Certificates do not serve as verification of an apprenticeship or training. This experience must be verified by signed documentation. Verification of Employment Verification of Employment forms must be completed and signed for all work experience claimed as qualification for examination if the initial application is audited. All documentation must be provided in English. Faxed verification is not accepted. The original signature must be provided on this form. You ‘www. [Link] should use this form as well as the Verification of Responsible Charge form to document two references required to meet the responsible charge eligibility if you do not have a four year technical degree. 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 document that at least two (2) years of the ten (10) years ‘experience have been in a position of responsible charge. Compliance with Certification Criteria and Qualifications Read carefully and sign the compliance agreement. Fees All applications must be accompanied by full payment of the required fees. No exceptions will be granted. Submitting Materials Mail application and fee to ISA. Incomplete or incorrectly completed applications may be returned to an 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 virexamination, test results, and renewal of certification depends on accurate information. If mailing with a check payment (or through regular postal delivery), send all materials to: ISA CAP Program P.O. Box 3561 Durham, NC 27702 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 Materials sent to any other address will be returned. Fax, e-mail, and photocopied applications, or applications completed in pencil are not accepted. ‘[Link]/CAP 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. Electronic candidates will receive immediate results at the testing center. Results for each paper/pencil exam applicant will be mailed within thirty (30) days after the examination date.DUE PROCESS PROCEDURES Ifan applicant feels he/she was wrongly denied certification, original or renewal, from the CAP program, then he/she has the right to appeal. 1. Appeals A. Allappeals 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 onthe of d 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. Ifa 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. v Tl, 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 counsel or represent him/herself at the hearing. The appiicant 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. 4. 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. [Link]/CAP 1x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. I. Final Review A. lithe 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. ‘[Link]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 ina 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. Article 11 Members shail 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 ina manner which will uphold public appreciation of the services they render. ww. [Link] Article TI 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 shail 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 xassociations and professional Article VI registrations without exaggeration ‘Members shalll pledge themselves to and in accordance with the laws of live and work according to the laws the locations in which they practice. of man and to the highest standards of professional conduct, using their knowledge and skills to the benefit of all mankind. Why Should You Join ISA? Founded in 1945, ISA ([Link]) 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. Here are some of the benefits you enjoy as an ISA Member: 1. Stay current within your field by reading your free InTech magazine every month, 2. Make professional contacts and open the door to your future by participating 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. 4, Shop smarter by using the ISA Directory— 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 may download most standards at no charge to you. Get ahead by getting involved in ISA. To join ISA, complete an ISA Membership enrollment form and return it with your CAP Application, or call (919) 549-8411. [Link]/CAP xlFeasibility Study PERFORMANCE DOMAIN I FEASIBILITY STUDY Identify, scope, and justify 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 "go"/"no go" decision making. [Link]. 1Feasibility Study 1. When beginning a project, why is gathering requirements critical to the success of an automation project? A. To establish the design and engineering schedule B. To define the purpose, scope, and objectives C. To determine funding and buy-in from stakeholders D. To provide a basis for performing calculations 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? A. Feedforward B. Feedback C. Cascade D. Open loop 3. What measurements do engineers primarily rely on when using financial tools to evaluate operational performance? A. CPI (Cost Performance Index) B. ERP (Enterprise Resource Planner) C. KPI (Key Performance Index) D. MES (Manufacturing Execution System) 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% [Link] 2Feasibility Study 5. What is the main disadvantage of non-discounted capital investment evaluation methods? DOs > o These methods are tedious and complicated to use. These methods cannot be used for automation projects. These methods do not provide required accuracy for cost benefit analysis. These methods do not explicitly take into consideration the time value of money. What is the NPV of an automation project with the following projected cash flows ai a discount rate of 10% and an initial investment of $10,000? Year_| Cash Inflows 1 $1,000 | 2 $2,000 | 3 $2,000 : [ $5,000 | A B c D. 7. During the budgeting process of the Building Automation System (BAS) for an addition to an existing office building, the team decides to use a wireless system using Zigbee. What is a MAJOR advantage of using wireless BAS controllers for this application? A B. All wiring is eliminated and the number of trades working on the new addition is greatly reduced. All wireless controllers are auto-configurable and can be installed anywhere ‘without regard to location. Upgrades or expansions of legacy systems are cost effective and can be staged to accommodate budgets and schedules. . The low-power batteries utilized are a much less expensive energy source than the local utility. [Link]/CAP 3Feasibility Study 8. What is a MAJOR advantage of a Distributed Control System (DCS) over a Programmable Logic Controller (PLC) or Direct Digital Control (DDC)? A. Awide variety of I/O for encoders, stepper motors, high-speed counters, and servo drives B. Ability to program extremely complex, advanced, or proprietary custom control strategies C. Faster scanning of control function logic suitable for discrete manufacturing industries D. Ease of implementation and modification of common control strategies via configuration instead of programming 9. What does a management team use to determine whether to terminate a project or move to the next phase in the project life cycle? Feasibility study Earned Value Analysis Project management plan Work Breakdown Structure gos 10. Which of the following tools is commonly used to identify the causes of risks in an automation project? A. Design of Experiments B. Pareto chart C. Fishbone diagram D. Control chart ‘[Link] 4Feasibility Study ‘ANSWER KEY - DOMAINT 1. B. To define the purpose, scope, and objectives 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. automation project begins, Reference: Parshall & Lamb. Applying $88: Batch Control from a User's Perspective. ISA, 2000. 2.A. Feedforward ‘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. Principles and Practices of Automatic Process Control, 2™' Edition. Wiley & Sons, 1997. 3.C. KPI (Key Performance Indicators) Operational and engineering staffs typically use Key Performance Indicators (KPI) to provide a timelier window into the current performance. Enterprise Resource Planning (ERP) systems are used to compute metrics on a monthly basis and are primarily used by accountants. Manufacturing Execution System (MES) is utilized to schedule production activities. Cost Performance Index (CPI) is the ratio of earned value to actual cost only, whereas KPI considers time, cost, and performance. Reference: Martin. Bottom Line Automation. ISA, 2006 [Link]/CAP :Feasibility Study 4.B. 30% 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. 5. D. These methods do not explicitly take into consideration the time value of money. Non-discounted capital investment evaluation methods like payback and ROI do not take time value of money into account. Payback determines the time required to recover the project cost. ROI is expressed as a percentage and is measured by the ratio of yearly operating cash flow to its first cost. Reference: Friedman. Automation and Control System Economics. ISA, 2006. 6. A. - $1,278 ai ) - Initial investment NPV =( (+k 1000, 2000, 2000 , 5000 fi +0.) G+01)" (+0. 2000 + 2000 ~)- 10,000 Gor eon NPV =( NPY = (909 + 1,653 + 1,503 + 3,415 + 1,242) - 10,000 NPV = 8,722 - 10,000 = -1,278 Reference: Kerzner. Project Management. John Wiley & Sons, Inc., 2006. 7. C. Upgrades or expansions of legacy systems are cost effective and can be staged to accommodate budgets and schedules. Wireless installations allow a simplification of additions to an existing system in an occupied building, which causes less interruption during the installation process. www [Link]/CAP 6Feasibility Study Wireless transmitters must be located where they can communicate with another controller o router, not just anywhere. Some, but not all, are auto-configurable. Network routers and existing system equipment generally require some wiring. Batteries need to be changed annually. Reference: www_zigbee.org, SiemensZigbee_success_story[1].pdf, 2007 if implementation and modification of common control siraiegies via configuration instead of programming Distributed control systems generally include libraries of common control functions and strategy examples that can quickly be copied and modified by changing configuration parameters for a variety of process applications. Programmable Logic Controllers by design typically feature faster scanning of logic for discrete manufacturing industries, their original target market. Direct Digital Control systems are typically used where custom (often proprietary) or complex advanced control strategies must be implemented and are programmed specifically for the application. Programmable Logic Controllers are available with a wide variety of I/O including modules for uses with encoders, steppers, counters, and servo drives in high-speed motion control applications. Reference: Bettikha. The Management of Control Systems. ISA, 1992. 9. A. Feasibility study The results of a feasibility study evaluate the alternative conceptual solutions along, with the associated benefits and costs. The objective of this step in a project life cycle is to provide management with the predictable results of implementing a specific project and to provide generalized project requirements. The study is used as the basis on which to decide whether to proceed to the next steps in the project life cycle or terminate the project. The project management plan provides the details of how the project will be planned, executed, monitored, controlled, and closed. www. isaorgCAP zFeasibility Study Work Breakdown Structure (WBS) is a deliverable-oriented hierarchical decomposition of the work to be executed by the project team to accomplish the project objectives, Earned Value Analysis is part of project performance tracking. Reference: ‘A Guide to the Project Management Body of Knowledge. Project Management Institute, 2004. 10. C. Fishbone diagram Fishbone diagrams, also called cause-and-effect diagrams or Ishikawa diagrams, are used to illustrate how various factors might be linked to potential problems. Design of Experiments (DOE) is a statistical tool that helps identify which factors may influence specific variables of a product or process under development or in production. Pareto chart is a quality analysis tool that depicts how many defects were generated by type of category or identified cause. A control chart’s purpose is to determine whether or not a process is stable or has predictable performance. Reference: ‘A Guide to the Project Management Body of Knowledge. Project Management Institute, 2004, ‘wor. [Link]/CAP 8Definition PERFORMANCE DOMAIN II DEFINITION Identify customer requirements and complete high-level analysis of the best way to meet those requirements Task1: Determine operational strategies through discussion with key stakeholders and using appropriate documentation in order to create and communicate design requirements. Task 2: Analyze alternative technical solutions by conducting detailed studies inorder 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. Task5: Summarize project requirements by creating a basis-of-design document and a user-requirements document in order to launch the design phase. [Link]/CAP 9Definition 1. Which of the following is a benefit of using an agenda for discussions? A. To define meeting objectives B. Toensure equal participation C. To establish the project communication plan D. To define the project team roles and responsibilities 2. What control strategy is represented in the attached diagram? REACTOR amir > ve | A. Ratio B. Cascade C. Split-range D. Feedforward 3. Whatis 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 CC. Step response models D. First principle models [Link]/CAP 10Definition 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. Smith Predictor set using Lambda rules B. Tactical schedulers with business economics C. Linear programs with detailed process economics D. Real-time optimization with a detailed process model 5. Whatis the recommended limitation in meters for the length of a "fast Ethernet’ (100 mbs) segment on twisted pair cable? A. 10 B. 100 Cc. 300 D. 350 6. According to NFPA Electrical Standards for Industrial Machinery (NFPA 79), which of the following is acceptable for emergency operations? . Resetting an emergency stop to initiate a machine restart Using a control room reset to remotely reset an emergency stop ‘Using an emergency stop to initiate an automatic sequenced shutdown of the machine Using an emergency slop to ren causing the hazardous condition as quickly as possible oS ANe> 7. Which of the following contract types places the PRIMARY risk with the supplier? A. Cost plus B. Fixed price C. Time and material D. Unit price [Link]/CAP ulDefinition 8, What standard addresses the electrical safety requirements for employee workplaces that are necessary for the practical safeguarding of employees? 49 CFR 571 NFPA 70E NFPA 70 (NEC) NFPA 79 goe> 9. Which of the following topics is included in the User Requirements Specification (URS) for an automated system? Modes of operation such as startup, shutdown, test, and fallback Personnel required for a test or group of tests Description of storage devices, with their maximum storage capacities Software sub-programs and their input, output, and input/output parameters gNe> 10. Real-time PLC-to-PLC communication MOST often occurs on which level of network? A. Device Network B. Sensor Network C. Control Network D. Enterprise Network 11. What term is used to define the practice of reviewing a facility or process to find actual or potential hazardous conditions as well as hazardous procedures? Risk Analysis Site Safety Survey Hazard Analysis (HAZAN) Hazard and Operability Study (HAZOP) oOe> 12. What MINIMUM depth of working space is required by the National Electrical Code (NFPA 70, 2008 Edition) between a 480 VAC starter panel and the concrete-block wall opposite the panel in a new pump station if the panel’s 24-inch wide door is open? A. 2 feet B. 3 feet C. 3 feet, 6 inches D, 4 feet [Link]/CAP 2Definition ANSWER KEY - DOMAIN I 1. A. To define meeting objectives An agenda defines the objectives for the meeting and lists the topics to be covered, the time allocated to each topic, and the person responsible for each topic. It does not guarantee equal participation of the attendees. Project team roles and responsibilities and the project communication plan are parts of the project management plan, not a meeting agenda. Reference: Barkley and Saylor. Customer-Drive Project Management, 2-4 Edition. McGraw Hil 2001. 2. C. Splitrange Split ranging is an action in which two or more signals are generated (in this case, TV- 1A and TV-1B valve signals) or two or more final control elements are actuated by an input signal, each responding consecutively with or without overlap. In this case, the signal determines whether the chilled water valve is opened, both valves are closed, or the heated water valve is opened. Feedforward is a method of control that compensates for a disturbance before its effect can be measured based on a process model that relates a variable to the disturbance it would cause. Feedforward is usually combined with feedback control to deal with disturbances that cannot be compensated for by the process model. The controller in the diagram does not have a process model to compensate for disturbances. Ratio control maintains a predetermined ratio between two or more variables or maintains the magnitude of a controlled variable at a fixed ratio to another variable. The controller in the diagram does not maintain a ratio between two variables; it provides only chilled water or only heated water to adjust the reactor temperature. Cascade control is a control technique that incorporates a master loop and a slave loop. The master loop controls the primary variable and establishes the slave loop setpoint. The purpose of the slave loop is to reduce the effect of disturbances on the master loop and improve the dynamic performance of the control. The method in the diagram only involves a single temperature controller. Reference: ‘The Automation, Systems, and Instrumentation Dictionary, 4 Edition. ISA, 2003. www [Link]/CAP eDefinition 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 , Telationships 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 Optimam Benefit. ISA, 2003. 4. DB. Real-time optimization with a detailed process model. 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 builtin 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 nontinear process behavior. A Smith Predictor set using Lambda rules is used for dead-time compensation. Reference: Blevins, et al. Advanced Control Unleashed: Plant Performance Management for Optimum Benefit. ISA, 2003. ‘[Link]/CAP a