Week 12

Question 1

The function of PID parameters is BEST described as
a. placing the system in a safe condition during process upsets.
b. optimizing a control loop.
c. ensuring that specified components are properly calibrated.
d. ensuring that specified components are properly installed.

Answer 1

b. optimizing a control loop.

Question 2

What is an advantage of using a linear approach during troubleshooting to isolate the
cause of a problem?
a. It efficiently exposes recurring problems and, based on experience, possible
shortcuts to fix the problem.
b. You can move top down or bottom up from point of entry and check process
steps until the problem is found.
c. It readily identifies process bottlenecks and minimizes backtracking in the
troubleshooting process.
d. Once a process step is found to work correctly, you can safely assume that the
layers below it are working as well.

Answer 2

b. You can move top down or bottom up from point of entry and check process
steps until the problem is found.

Question 3

Which statement BEST describes the potential impact of intelligent device
management on human performance measures in system maintenance?
a. Faster acquisition of parts from intelligent lockers
b. Improved achieved availability measures
c. Reduced restore time
d. Reduced preventive maintenance and corrective maintenance expenditures

Answer 3

c. Reduced restore time

Question 4

While following a troubleshooting framework, no one definitive solution to a problem
surfaces and several solutions are plausible. Which is NOT a recommended course
of action?
a. Order solutions from easiest to most difficult.
b. Choose the one with the broadest appeal to all stakeholders.
c. Analyze the cost of quality associated with each solution.
d. Propose solutions in order of their probability of success.

Answer 4

b. Choose the one with the broadest appeal to all stakeholders.

Question 5

Good preventive maintenance can provide all of the following benefits EXCEPT
a. reduced operator error and random failures.
b. high operational availability.
c. correction of failures before they cause damage.
d. cost savings over a product’s life cycle.

Answer 5

a. reduced operator error and random failures.

Question 6

Which troubleshooting technique replaces suspected bad components until the
problem is found?
a. Substitution method
b. Consultation method
c. “Remove and conquer” method
d. Fault insertion method

Answer 6

a. Substitution method

Question 7

Consider the following automation system data:
- Preventive maintenance for one hour every month
- Quarterly preventive maintenance for two hours each quarter
- One failure that results in six hours of downtime
- One failure that results in four hours of downtime
What is the uptime for this automation system if it runs 24 hours a day, 365 days a
year?
a. 99.66%
b. 99.77%
c. 99.86%
d. 99.89%

Answer 7

a. 99.66%

Question 8

A system problem has been identified. Affected stakeholders from operations,
engineering, and maintenance meet to further analyze the problem and the data
collected thus far. The merit of these individuals coming together is
a. out-of-the-box thinking.
b. case-based reasoning.
c. criteria filtering.
d. cause-and-effect analysis.

Answer 8

b. case-based reasoning.

Question 9

On-call contract maintenance done by a third party BEST describes
a. equipment or system audits.
b. service level agreements (SLAs).
c. system utilization services.
d. preventive maintenance.

Answer 9

b. service level agreements (SLAs).

Question 10

In troubleshooting a system failure, a suspected bad component is replaced with a
known good component. This does not correct the problem. What is the next BEST
course of action?
a. Build software traps involving additional logic and code to detect the problem.
b. Further analyze the problem and collect additional data as necessary.
c. Set additional alarms to pinpoint the problem.
d. Retain a consultant who specializes in this type of repair.

Answer 10

b. Further analyze the problem and collect additional data as necessary.

Question 11

Which statement BEST describes troubleshooting procedures for automation
systems?
a. Systems engineering process
b. Continuous improvement (CI) process
c. Logical and analytical framework
d. Parallel set of actions

Answer 11

c. Logical and analytical framework

Question 12

How are the maintainability and maintenance of automation systems related?
a. Maintainability is a front-end, design outcome; maintenance is related to
ongoing system availability.
b. Maintainability is related to system availability; maintenance is related to
traceability and warranties.
c. Maintainability is a front-end engineering function; maintenance is an ongoing
engineering function.
d. Maintainability is related to malfunctions; maintenance is related to service
quality.

Answer 12

a. Maintainability is a front-end, design outcome; maintenance is related to
ongoing system availability.

Question 13

A recommended safety precaution when using a generic framework for
troubleshooting is
a. Review related failure mode and effects analysis (FMEA) documents before
proceeding.
b. Secure proper permits and follow their requirements.
c. Compare the process capability index (Cp) with the mean-sensitive process
capability index (Cpk).
d. Conduct a Pareto analysis to prioritize areas of concern.

Answer 13

b. Secure proper permits and follow their requirements.

Question 14

Which statement BEST describes the importance of real-time data entry and
validation by field maintenance technicians?
a. To separate failures in quality from unintended use
b. To facilitate timely billing of service level agreement customers
c. To promote professionalism and build customer loyalty
d. To gain accurate information for future improvements

Answer 14

d. To gain accurate information for future improvements

Question 15

All of the following are generally recommended safety precautions when using a
generic troubleshooting framework EXCEPT
a. Communicate actions with the operator in charge.
b. Simulate the process on a computer before proceeding.
c. Be aware of increased safety risk to the troubleshooter.
d. Follow company procedures.

Answer 15

b. Simulate the process on a computer before proceeding.

Question 16

Which statement does NOT characterize MRO?
a. Digital electronic and optical technologies have dramatically increased MRO
costs.
b. Improvements in maintainability can reduce both failure rates and MRO costs.
c. Computerized information on MRO activities tends to improve maintenance
operations.
d. MRO costs usually exceed acquisition costs.

Answer 16

a. Digital electronic and optical technologies have dramatically increased MRO
costs.

Question 17

Which of the following statements BEST describes the calibration of a temperature
sensor?
a. It is the end user’s practice to perform bench calibrations.
b. Recalibration can be performed as needed if an out-of-tolerance condition
becomes evident.
c. A field calibration can be performed at the same time as a loop check.
d. It is normally calibrated in a laboratory environment.

Answer 17

d. It is normally calibrated in a laboratory environment.

Question 18

Differentiation between primary and secondary symptoms should be done during
which troubleshooting activity?
a. Proposed solutions
b. Problem analysis
c. Collecting additional information
d. Problem definition

Answer 18

c. Collecting additional information

Question 19

The inherent availability of an automation system is associated with
a. sales and marketing.
b. manufacturing engineering.
c. quality management.
d. service management.

Answer 19

b. manufacturing engineering.

Question 20

Which of the following practices will NOT necessarily enhance login security for
process control system software?
a. Use a firewall as a gatekeeper between the network system and the Internet,
and set up a system to automatically install software upgrades.
b. Use alphanumeric passwords with at least one capital letter if the protection
system is case-sensitive.
c. Change passwords regularly.
d. Assign a user access level commensurate with job function.

Answer 20

a. Use a firewall as a gatekeeper between the network system and the Internet,
and set up a system to automatically install software upgrades.

Question 21

Cause-and-effect diagrams and control charts would be MOST useful during which
troubleshooting activity?
a. Problem definition
b. Problem analysis
c. Proposed solutions
d. Testing proposed solutions

Answer 21

b. Problem analysis

Question 22

The primary benefit of intelligent device management is
a. increased accuracy of alarm enunciators or recorders.
b. more reliable mean time between failure (MTBF) data.
c. remote monitoring before failure occurs.
d. ease in recording of nondestructive test data.

Answer 22

c. remote monitoring before failure occurs.

Question 23

What is a common pitfall associated with using the replacement automation
approach in automation projects?
a. The salvage value of any sold or disposed assets will be negligible.
b. The system value will depreciate faster due to early obsolescence.
c. Breakthrough improvements are rare.
d. Required upgrades tend to erode any initial system price savings.

Answer 23

c. Breakthrough improvements are rare.

Question 24

All operating (recurring) and implementation (nonrecurring) costs and capital costs,
plus other concepts of cost (e.g., time value of money, lost opportunity costs, etc.),
are identified during which phase of a project’s life cycle in the ISA CAP program’s
model?
a. Feasibility study
b. Project definition
c. System design
d. Deployment

Answer 24

a. Feasibility study

Question 25

In addition to technical skills, which statement BEST describes an appropriate skill
mix that facilitates success as an automation professional?
a. Management and coaching skills
b. Business and interpersonal skills
c. Problem-solving and social skills
d. Writing and verbal skills

Answer 25

b. Business and interpersonal skills

Question 26

Which of the following statements is correct with regard to the development of an
effective team?
a. A period of storming will often precede performing.
b. The norming stage begins the development.
c. Teams usually proceed directly from the norming stage to the storming stage.
d. Teams usually do not form before they go through the storming phase.

Answer 26

a. A period of storming will often precede performing.

Question 27

Which factor contributes to the rise in annual automation costs toward the end of a
system life cycle?
a. Latent knowledge
b. Spare parts expenditures
c. System engineering
d. Budgeting for replacement equipment

Answer 27

b. Spare parts expenditures

Question 28

Which statement accurately characterizes both the NPV and IRR methods for
evaluating automation system capital investments?
a. Both provide a high degree of reliability in decision making to accept/reject a
project.
b. The final computations both yield a dollar figure for individual projects.
c. Multiple projects can be added and averaged to evaluate any combination of
capital investments.
d. They both adjust cash flows over time for the time value of money.

Answer 28

d. They both adjust cash flows over time for the time value of money.

Question 29

During which phase of a project’s life cycle in the ISA CAP program’s model might
an engineering firm tour the client site and interview key stakeholders to better
understand the project need?
a. Feasibility study
b. System design
c. Project definition
d. Software development

Answer 29

c. Project definition

Question 30

Successful automation projects require all of the following EXCEPT
a. genuine respect and caring among co-workers.
b. positive and negative reinforcement.
c. high levels of personal integrity and accountability.
d. a strong purpose and plan.

Answer 30

b. positive and negative reinforcement.

Question 31

A team leader should be able to perform all of the following activities when leading a
team of automation professionals EXCEPT
a. Promote persistence and self-discipline.
b. Remove all conflict.
c. Remove barriers and eliminate unnecessary permissions and approvals.
d. Develop partnerships.

Answer 31

b. Remove all conflict.

Question 32

Capital budgeting is BEST described as
a. the process of making long-term investment decisions.
b. decision making to support operating efficiency.
c. the process of planning for short-term investments.
d. decision making related to current expenditures.

Answer 32

a. the process of making long-term investment decisions.

Question 33

A challenge in using new “real-time” cost accounting system data to project the
expected payback of proposed projects is
a. Financial ratio comparisons with industry guidelines are hard to establish.
b. It takes time to collect sufficient historical data to make reasonable projections.
c. Cost-of-quality cost measures are more difficult to discern due to hidden costs.
d. It fails to recognize the causal relationships of costs to resources and
activities.

Answer 33

b. It takes time to collect sufficient historical data to make reasonable projections.

Question 34

A project manager prepares a work breakdown structure (WBS) identifying each
major task and related subtasks required to fulfill the project objective. Subtasks are
further reduced into units and subunits with associated cost projects and assigned
responsibilities. This activity occurs during which phase of a project’s life cycle in the
ISA CAP program’s model?
a. Project definition
b. Feasibility study
c. System design
d. Software development

Answer 34

a. Project definition

Question 35

When attempting to sell a process automation project to senior-level management,
an engineer would be well served to
a. present the project as a series of coherent pieces for delivery implementation
and evaluation.
b. relate current errors and deficiencies as a cost relative to production.
c. discuss how the process must be improved to retain its inherent capability.
d. explain how process improvements will fulfill regulatory requirements in a
predictable cause-and-effect relationship.

Answer 35

b. relate current errors and deficiencies as a cost relative to production.

Question 36

Why is it important to have a written job description when interviewing candidates
for an automation position?
a. To decrease the time it takes a new hire to become productive
b. To determine the training needs for the position
c. To communicate specific standards of performance tied to the job
d. To define required tasks, knowledge, skills, and abilities

Answer 36

d. To define required tasks, knowledge, skills, and abilities

Question 37

Which of the following items is NOT an example of a capital expenditure?
a. Purchase of a new processing machine that will cut labor and maintenance
costs
b. Project bonuses paid to salaried engineers
c. Purchase of a new DCS for plant operations
d. Plant HVAC system upgrade for EPA compliance

Answer 37

b. Project bonuses paid to salaried engineers

Question 38

A consulting engineer has been named project manager for an automation project.
Once the vendor is selected, which role will be essential to ensure that the system
meets specifications?
a. Optimist
b. Advocate
c. Risk taker
d. Problem solver

Answer 38

b. Advocate

Question 39

According to the ISA CAP program’s model, brainstorming sessions examining the
proposed system’s operability and safety occur during which phase of a project’s life
cycle?
a. Feasibility study
b. Project definition
c. System design
d. Software development

Answer 39

c. System design

Question 40

A final report on a highly visible automation project will be distributed to senior
leaders and several operations managers. In preparing this report, an engineer
would be well served to
a. define any geometric tolerance symbols present in report diagrams.
b. explain how troubleshooting procedures solved unexpected crises and plan
deviations.
c. include an executive summary and, as appropriate, use bulleted lists in the
narrative.
d. review how cost, performance, and schedules were estimated, measured, and
controlled.

Answer 40

c. include an executive summary and, as appropriate, use bulleted lists in the
narrative.

Question 41

Which statement BEST describes the importance of considering all stakeholder
concerns during an automation project?
a. To identify controversial issues that the team should rethink/reevaluate its
position on
b. To ensure that the team has the resources, skills, and process capability to
fulfill its goals and objectives
c. To identify potential opportunities to be exploited and threats to be addressed
d. To help analyze the competitive impact of proposed technologies

Answer 41

a. To identify controversial issues that the team should rethink/reevaluate its
position on

Question 42

How can an ROI ratio help to establish the economic benefit of a capital investment
for an automation system?
a. It helps to assess project risks in the event of an economic hardship.
b. It provides a measure of cash inflows and payback period for the investment.
c. It helps measure life cycle costs over the useful life of the investment.
d. It helps to systematically compare project options against a set of weighted
criteria.

Answer 42

b. It provides a measure of cash inflows and payback period for the investment.

Question 43

When assessing the success of an automation project, which factors differentiate
the customer’s perspective from the service provider’s interests?
a. Quality versus project logic
b. Project duration versus resource allocation
c. Effectiveness versus efficiency
d. Cost versus profit

Answer 43

d. Cost versus profit

Question 44

According to the ISA CAP program’s model, a FAT is performed during which phase
of a project’s life cycle?
a. System design
b. Software development
c. Deployment
d. Support

Answer 44

b. Software development

Question 45

Which of the following is NOT an appropriate practice for sending business e-mails?
a. Use a precise subject line.
b. Use “smiles” (symbols) for emphasis.
c. Sign your e-mail and include personal contact information.
d. Tailor formality to the formality of the organization or people.

Answer 45

b. Use “similes” (symbols) for emphasis.

Question 46

An ROI ratio is used to evaluate the purchase price for an automation system and
all other initial costs associated with the project against the accumulated cash
inflows. What is the PRIMARY pitfall in using this ROI ratio to make a decision as to
whether or not to invest in an automation project?
a. It fails to capture the qualitative benefits derived from automation systems.
b. It ignores the time value of money.
c. It ignores equipment reliability and system maintainability costs.
d. It relies on vendor estimates of useful life.

Answer 46

b. It ignores the time value of money.

Question 47

What constraints do automation projects work under?
a. Time-driven
b. Fixed cost and turnkey
c. Hybrid and cost
d. T&M “not to exceed”

Answer 47

a. Time-driven

Question 48

Traditional classroom training is used to provide operators with an overview of a
new system. A simulator is used to provide more focused, hands-on HMI software
training. These training interventions occur during which phase of a project’s life
cycle in the ISA CAP program’s model?
a. System design
b. Software development
c. Deployment
d. Support

Answer 48

c. Deployment

Question 49

What is a facilitator’s role in project meetings with other automation professionals?
a. Make final decisions.
b. Stifle dissension.
c. Keep the group on agenda.
d. Take notes.

Answer 49

c. Keep the group on agenda

Question 50

Which factor differentiates the NPV method from the IRR for evaluating automation
system capital investments?
a. NPV discounts cash flows after the initial investment; IRR does not.
b. IRR is a percentage; NPV yields a dollar figure.
c. IRR makes it easier to verify the actual value of a project after it is
implemented.
d. NPV considers the time value of money; IRR does not.

Answer 50

b. IRR is a percentage; NPV yields a dollar figure.

Question 51

In which type of contract does an organization agree to pay an hourly rate that
guarantees a fair profit to the engineering firm awarded the contract for the project
duration?
a. Fixed-fee
b. Cost-plus
c. Turnkey
d. T&M

Answer 51

b. Cost-plus

Question 52

Which statement describes the relationship between the scope of work (SOW) and
the estimate in an automation project?
a. SOW includes an overall budget; the estimate includes definitive material
costs and labor estimates.
b. SOW describes the work on a task-by-task basis; the estimate specifies
performance metrics.
c. SOW defines the work to be done; the estimate defines the project
parameters.
d. SOW sets project parameters; the estimate provides costs for the deliverables.

Answer 52

c. SOW defines the work to be done; the estimate defines the project
parameters.

Question 53

An important criterion for forming a team of automation professionals to improve a
specific process is
a. Select team members based on highly specialized skills and ensure that there
is no overlap of talents.
b. Select team members who work together on a daily basis to ensure that they
can dedicate sufficient timeto the project.
d. Designate a change agent to champion the work of the team with
management.
d. Appoint team members who represent the functions, work units, and job
descriptions required.

Answer 53

d. Appoint team members who represent the functions, work units, and job
descriptions required.

Question 54

Why is it better to base an automation system investment on life cycle cost (LCC)
rather than on lowest price?
a. System price is a relatively small part of the overall system cost.
b. LCC considers the potential value of the investment over time; the cost-only
method does not.
c. LCC sets milestones to assess the net cash flow patterns; the cost-only
method does not.
d. Low price typically translates to lower quality and higher service costs.

Answer 54

a. System price is a relatively small part of the overall system cost.

Question 55

Which characteristic differentiates a T&M contract from a cost-plus?
a. Less risk of budget overruns for the buyer in a contract
b. Potential for a higher profit for the seller in a T&M contract
c. Buyer has enhanced ability to allocate resources in a cost-plus contract
d. Greater likelihood of disagreements between the buyer and the seller about
what constitutes high quality in a T&M contract

Answer 55

b. Potential for a higher profit for the seller in a T&M contract

Question 56

The linked relationship between a P&ID and loop sheets would be shown in the
a. scope of work (SOW).
b. project schedule.
c. execution strategy.
d. project estimate.

Answer 56

b. project schedule.

Question 57

Which statement BEST describes why it is beneficial for automation professionals to
understand different social styles?
a. To recognize behavior problems in the workplace
b. To balance individual concerns with organizational business concerns
c. To enhance personal effectiveness
d. To improve routine transactions with subordinates

Answer 57

c. To enhance personal effectiveness

Question 58

A manufacturing operation can expect to realize all of the following economic
benefits from a capital investment in an automation system EXCEPT
a. reduced power consumption.
b. increased customer goodwill.
c. increased production.
d. reduced raw material costs.

Answer 58

b. increased customer goodwill.

Question 59

What is a probable outcome when a “not-to-exceed” stipulation is added to a T&M
contract?
a. There is less risk of budget overruns for the seller.
b. The seller might resist buyer requests to “tweak” the product.
c. The seller loses significant control during project execution.
d. The buyer gains more control over resource allocation.

Answer 59

b. The seller might resist buyer requests to “tweak” the product.

Question 60

A design team has 160 hours allotted to complete a task. The team reports 50%
completion at a status meeting. Current timesheets show that the team has spent 70
hours on the task. What is the efficiency ratio for the design team?
a. .88
b. 1.60
c. 2.28
d. 1.14

Answer 60

d. 1.14

Question 61

Why is active listening important in conflict resolution?
a. Active listening helps participants focus on each other instead of the problem.
b. Active listening helps to establish objective criteria.
c. Active listening helps focus on positions.
d. Active listening provides a structure for reducing a long list of potential

Answer 61

b. Active listening helps to establish objective criteria.

Question 62

Which of the following measures are included in the life cycle cost (LCC)
calculation?
a. System price and annual production increases
b. Project costs and the ongoing costs
c. NPV of the annual manufacturing cost savings
d. System price and the NPV of the annual manufacturing cost savings

Answer 62

b. Project costs and the ongoing costs

Question 63

Which of the following characterizes a lump-sum (or fixed-price) contract?
a. High risk for the buyer that schedule overruns will jeopardize quality
b. Clearly defined methods and deliverables
c. Change orders are not applicable
d. No risks to the buyer or the seller

Answer 63

b. Clearly defined methods and deliverables

Question 64

Which of the following quality tools is useful in preparing a project scope of work
(SOW)?
a. Pareto chart
b. Interrelationship digraph
c. Work breakdown structure (WBS)
d. Process decision program chart (PDPC)

Answer 64

c. Work breakdown structure (WBS)

Question 65

During a team meeting, the team leader must frequently interject to reinforce
established ground rules. Within the context of team evolution, the team is most
likely in the stage of
a. forming.
b. storming.
c. norming.
d. performing.

Answer 65

b. storming.