CCST Cousre Student Noteset PDF

Certified Control System
Technician® (CCST®) Level I

Online Review Course
Course TS00E, Version 1.2
Student Noteset
Copyright © 2013, ISA
67 T.W. Alexander Drive
Research Triangle Park, NC 27709 USA
All rights reserved. This book or any portion thereof

may not be reproduced or used in any manner whatsoever
without the express written permission of the publisher.
The unauthorized reproduction or distribution of a copyrighted work is illegal. Criminal copyright

infringement, including infringement without monetary gain, is investigated by the FBI and is punishable
by fines and federal imprisonment.
ISA Cyber Instruction – TS00E
Online Instructor-Led Course
Certified Control Systems Technician (CCST) Level I Review Course
This online/self-study course is a fast-paced review of the knowledge and practical skills
necessary to install and maintain standard measurement and control instrumentation. It
is intended for practicing technicians preparing for the ISA Certified Control Systems
Technician® (CCST®) Level I exam. Practice certification-type exams and an
explanation of the examination process are provided.
The course is divided into various modules, with a recommended period of one-Module
for completion. However, students may work at their own pace, as long as they cover
the material by the indicated review dates.
Various learning techniques will be provided to cover the Module course areas including:
pre-recorded instructor presentations, additional resources, homework
questions, as well as live Q&A debrief instructor sessions. Refer to your detailed course
syllabus, which is provided with your course materials, for further
information/instructions.
Course Schedule
Pre-Exam
Students will be asked to take a pre-exam, which includes questions related to the
subject matter areas. Answers will be provided for students to assess their knowledge,
prior to beginning the course material.
Week/Module 1: Overview of CCST Certification

 Pre-survey
Week/Module 2: Domain 1 -- Calibration, Maintenance, Repair and Troubleshooting

Concepts of Process Control
• Live Instructor Q&A Review

Safety, Installation in Hazardous Areas
Fundamentals of Instruments
Week/Module 5: Domain 2 -- Project Start-up, Commissioning, Loop-checking, Project

Organization and Planning
Final Control Elements

Instrument Maintenance

Advanced Control Strategies
Week/Module 8: Domain 3 -- Project Start-up

Documentation
Week/Module 9: Domain 3 -- Instrument Maintenance

Documentation
Week/Module 10: Domain 3 -- Documentation

Exam Preparation Overview

 Post Survey
Final Examination
ISA Training Equipment Donors
ISA would like to thank the following companies for donating equipment for use in our hands-on training labs.
By donating equipment, these companies have increased their name recognition within the industry while
helping ISA continue its efforts to offer superior automation and control training.
Emerson Process
Management-
Rosemount Measurement
Wade
Associates, Inc.
Learn more with ISA’s hands-on

Portable Training Labs!
Our hands-on labs are ready to ship to your facility.
Offering state-of-the-art equipment and expert
instruction, ISA Onsite Training brings
automation training directly to you.
Learn more at
www.isa.org/PortableTraining.
30-3548-0310
Week 1
Week 1
Certified Control
Systems Technician®
(CCST®) Level I Review
Course – Week 1
TS00E Version 1.2
© 2013
Standards
Certification
Education and Training
Publishing
Conferences and Exhibits
General Course Goals
• Discuss principles and theory that explains measurement and control instrument
functions
• Perform calculations and analyze other information related to the calibration and
troubleshooting of instruments and systems
• Determine the education, experience, and examination requirements for becoming
a Certified Control Systems Technician® (CCST®)
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Course Description
• Intended for technicians with a broad base of experience in process controls who
are preparing for the CCST exam
• This is a review course designed to refresh and review knowledge and skills for a 5
year combination of education, training, and experience
Todays Objectives
• Overview of CCST
• ISO 9000
• History of process control
• Feedback Control
• Project Forms
• P&ID ISA 5.1
• Basic Measurement Units
• Temperature TC/RTD
• Pressure
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1: CCST® Certification Overview
• CCST® history
• Control systems technician definition
• CCST® program definition
Developing a Certification Exam
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CCST® History
• On February 16, 1995, ISA Executive Board approved the

CCST® program
– Steering committee and working committee established
– Job analysis finalized determining:
– Performance domains
– Certification program structure
– Certification Level requirements
– Application and information guides developed
– Examinations created and validated
– Exam sites established
• The first examination was offered in October, 1995
Performance Domains
The CCST exams will cover four major domains that have been
organized based on the findings in the CCST job task analysis study.
Within each of these domains are various task that pertain to the duties
of the instrumentation technician.
The CCST Level I, II, and III exams are weighted by a varying number of
questions per domain. The percentage of questions per domain is based on
each domain's relative importance and criticality in terms of what control
systems technicians are expected to know while performing their jobs, by
level. The following tables indicate the percentage of questions appearing on
the exams by level as they relate to each domain for the new versions of the
exams:
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CCST Exam
Domain Level 1 Level 2 Level 3

Average % Average % Average %
1: Calibration, Maintenance, 77% 61% 19%

Repair, Troubleshooting
2: Project Start-up 16% 23% 13%

Commissioning, loop-check
Project Org, Planning
3: Documentation 7% 10% 10%
4: Admin, Supervision, N/A 6% 59%

Management
Task for Level 1 Technician
0101 Calibrate a device using appropriate test standards, recommended procedures, and
manufacturer’s specifications on instrument data sheets in order to record “as-found” readings,
evaluate “as-found” readings against specified tolerance, make calibration adjustments as
required, and record “as-left” data.
0102 Safely assess the condition of a device through inspection, testing, and documentation
review in order to make adjustments to maintain device performance and accuracy and
determine the need for any repairs.
0103 Apply preventative, predictive, and corrective maintenance methods for instruments and
devices in order to minimize device failures and process downtime.
0104 Examine all pertinent documentation to determine which device(s) of the control loop could
be causing observed discrepancies in order to prepare a plan of corrective action.
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Task for Level 1 Technician (continued)
0105 Identify the correct device to be calibrated through documentation and instrument
identification systems in order to facilitate proper calibration.
0106 Obtain applicable documents required to perform device calibration, testing,

troubleshooting, or maintenance and review documents for accuracy and completeness.
0107 Perform repairs on instruments and devices by following proper industry protocol,
appropriate safety and operating procedures, and manufacturer’s recommendations in order to
return the device to service.
0108 Prepare for removal and decontamination of device from operational service by
reviewing the MSDS, appropriate PPE, and safety procedures.
11
Task for Level 1 (continued)
0109 Select the correct testing equipment by using existing documentation, appropriate
calibration procedures, and visual inspection in order to calibrate the device.
0110 Use documentation and field inspection to verify that appropriate utilities and equipment
are available and operational in order to safely and effectively perform device testing.
0111 Apply the proper fittings, terminations, and electrical barriers for instruments and devices,
utilizing the correct procedures in accordance with local regulatory codes and standards to
maintain safety in hazardous environments.
0112 Isolate a process component from an operational system by following maintenance

documentation and appropriate safety and operating procedures in order to perform testing or
maintenance.
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Task for Level 1 Technician (continued)
0113 Use appropriate testing equipment to measure and detect electrical and/or electronic
properties to ensure proper loop installation and performance.
0201 Field verify the as-built condition of the installed control system through visual
observation and comparison with applicable project documentation. Redline documentation
as needed in order to provide information for further verification and update by
engineering/maintenance to maintain accurate instrumentation records.
0202 Inspect the loop components through visual observation in order to verify that the
components are correctly installed in accordance with applicable documentation to ensure
safe and efficient device operation.
0203 Verify proper loop functionality by simulating a controller’s measured variable value
using appropriate simulation equipment.
0301 Document calibration, maintenance, troubleshooting, and repair using appropriate

forms, calibration labels, and/or electronic records to provide permanent record of changes
and device history.
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Control Systems Technician (CST) Defined
• Skilled in and knowledgeable of pneumatic, mechanical, and electronic

instrumentation
– Understands process control loops and process control systems including those that are computer
based
– Typically, has received training in such specialized subjects as:

– Theory of control
– Analog and/or digital electronics
– Microprocessors and/or computers
– Operation and maintenance of particular lines of field instrumentation
– Acquainted with both pipe fitting and electrical fundamentals
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CST Duties May Include
– Calibration
– Loop checks
– Troubleshooting
– Startup
– Maintenance/Repair
– Project Organization
– Administration
15
CCST® Program Definition
• The program promotes the professional development of the

CST, providing recognition and documentation of the
technician’s knowledge, experience, and education in
measurement and control
• The program ensures high level of skill and competency, and is

regarded as an important contribution by both industry
management and labor
• This is a “high stakes program”. Some companies hire,

promote and give pay raises as a result of the certification.
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To Become Certified
• Document education, training and/or experience as a

skilled practitioner, knowledgeable in pneumatic and
electronic instrumentation
– Level I requires five-year combination
– Level II requires seven-year combination
– Level III requires thirteen-year combination
• Understand process control loops and systems, including both

analog and microprocessor based systems
• Must pass the appropriate examination
17
2: Deming-father of manufacturing quality
Born: October 14, 1900

Sioux City, Iowa, USA
Died December 20, 1993

(Age 93)
Washington, DC, USA
Fields Statistician
Alma Univ of Wyoming, Univ of

Colorado,
Mater Yale University
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ISO 9000
The main elements of an ISO standard quality system are:
– Quality Management System

– Management Responsibility
– Resource Management
– Product Realization
– Measurement, Analysis, and Improvement
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ISO 9000 Standards
• Developed by the International Organization for

Standardization (ISO)
• Represent the common denominator of business quality
• Recognized internationally
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History of ISO Standards
• In 1988, the Commission of European Communities (EC)

passed a directive
• Focused on companies in chemicals, pharmaceutical, food
products, automotive, and other
• Companies must have their quality systems registered and
certified to the applicable ISO 9000 standard by an
accredited agency
• ISO 9000 certification demonstrates a supplier’s capability
to control the processes that determine the acceptability of
the product or service being supplied
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ISO 9001: 2008

• ISO 9001: 2008 was the latest issue of the ISO 9000 Standard
• The Standard:
– does not tell “how to do” some locally performed procedure
– it relies on locally generated (internal) procedures on “how to do
something”;
– then the ISO Standard measures the facility on how well they follow their own internal procedures
• Confirms process conformance through
– Quality management system
– Management responsibility
– Resource management
– Product realization
– Measurement, analysis and improvement
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ISO 9000 Impact
• Has become the requirement for business in Europe

• Not mandatory, but when a certified supplier is competing
with one not certified, the certified one will be preferred
• The whole point of ISO 9000 standards is that you:
– Document what you do (i.e. your locally generated procedures)
– Do what you document
– Prove it
– Improve it
23
ISO Effect on I and C Departments
• Quality policy
• Document control
• Quality control of all inspection, measuring, and test equipment
• Quality records
• Internal quality audits
• Training program
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25
Future of Instrumentation
• "The emerging employment problem in manufacturing is not a

shortage of jobs, but rather a shortage of qualified applicants,"
Engler said. "A full 36% of our members said they have employment
positions unfilled right now because they cannot find qualified
workers. This confirms what our members have been telling us in
recent years—that the people applying for manufacturing jobs today
simply do not have the math, science, and technological aptitude
they need to work in modern manufacturing."
Copied from an article in InTech Magazine
• We, “Instrumentation Professionals” are not exempt from

employment cutbacks, we must stay current with technology to stay
actively employed, if you do, you can enjoy many years of steady
employment.
• The future looks very bright for technicians and engineers.
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Week 2
Week 2
Certified Control
Course – Week 2
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
3: Concepts of Process Control
• Process defined
• Types of processes
• Industries that use process control
• Process control and the feedback loop
• Process variables
• Process dynamics
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At the Beginning of the Industrial Revolution
3 3
The Industrial Revolution
• 1920’s Manual Process Control

• 1930’s Pneumatic Control
• 1940’s Transistors were invented
• 1950’s Transition to solid state
• 1970’s PLC’s and DCS
• 1980’s HMI’s
• 1990’s Adaptive Control Algorithm's
• 2000’s Wireless Technology, Bus technology
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Definition of a Process
• A process is a part of a manufacturing plant in which material or

energy is converted to other forms of material or energy
– Change in pressure, temperature, speed, electrical potential, etc.
Continuous / Batch Process
• Continuous-Material is fed and removed at the same time, individual

product can not be identified.
• i.e. Potato chips , steam production, chemical reactions, separations, waste treatment,
distillation, blending, coating
• Batch- Material is added or blended, a process takes place and then

removed. You can identify a specific product.
• i.e. Alcoholic beverages, food products, pharmaceuticals
• Combinations- Many process plants have both but we will spend more
time on Continuous
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Continuous Process Example
Batch Process Example
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Process Control
• The regulation or manipulation of variables influencing the

conduct of a process in such a way as to obtain a product of
desired quality and quantity in an efficient manner
Disturbance
• Any change in the process or its associated equipment that

adversely affects the controlled quantity or variable
– A disturbance in controlled quantity or variable
– Controlling flow - the flow rate changes

– Controlling level - the rate of flow out of the tank changes
– Controlling temperature - more product comes in
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Disturbance (cont’d)
• Change in Steam Quality

– Steam Quality is defined as the ratio of the vapor mass to the mixture
mass (ANSI/ISA-77.13.01-1999)
– Change in the quality of the control agent such as:
– Fuel composition changes
– Fuel/Air ratio changes
• Change in ambient conditions

– Combustion - Outside air temperature changes
• Change caused by a process reaction:

– Exothermic: pertaining to a chemical change that is accompanied by a liberation of heat
– Endothermic: pertaining to a chemical change that is accompanied by an absorption of heat
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Feedback Control
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Feedback Control
13 13
Components of a control system
• PE (primary Element)
– Transmitter
• Controller
• FCE (Final Control Element)
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Pneumatics ISA-7.0.01-1996 Quality Standard for Instrument Air
Essential to good pneumatic

control:
Clean, dry air
15 15
4: P&ID Basics
• Definitions
• ISA standards for documentation
• P&ID development and use
• Identification letters and symbols
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Project Forms
• Plot Plan
• Process Flow Diagram
• P&ID
• Instrument Index
• Specification Forms
• Binary Logic System
• Location Plans
• Installation Details
• Loop Diagrams
17
Definition
• P&ID’s have many names

– Process and Instrument Diagram
– Piping and Instrument Diagram
• P&ID’s are one of the most important documents and are a
road map of the process
• Several regulatory agencies require updated P&ID’s as part of
the maintenance and operation procedures
• A drawing that shows the interconnection of process
equipment and the instrumentation used to control the
process
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Regulatory Agencies - OSHA
• OSHA PSM = 29 CFR 1910.119

• OSHA Occupational Safety and Health Administration
• PSM Process Safety Management
• 29 The number for all labor regulations
• CFR Code of Federal Regulations
• 1910 Occupational Safety and Health Regulations
• .119 Process Safety Management of highly hazardous
chemicals
19
Symbols Represent actual equipment
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P&ID Letter Designation
21 21
Identification
Letters
22 22
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Instrument Numbering
• Use Basic Number if project is small and there are no area, unit, or
plant numbers: Basic Number FT-2 or FT-02 or FT-002
• If project has a few areas, units, or plants (9 or less), use one of the
following: FT-102 (1 = area, unit, or plant number)
• Most projects use suffixes A and B if two instruments in the same

loop have identical tag numbers:
PV-006A, PV-006B
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General Instrument or Function Symbols - 1
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General Instrument or Function Symbols - 2
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Instrument Line Symbols - 1
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Instrument Line Symbols - 2
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Primary Element
Symbols
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Final Control Element
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Control valve failure and de-energized position indications
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P&IDs and ISA Standards
• There is no “standard” P&ID and no agreement on the

information that should be included or excluded from such
documents
• Most firms use ISA standards as a base and then add their
own modifications to meet their needs
• ISA standard ISA-5.1-2009 is the most generally accepted
guides for developing symbolism for instrumentation and
control systems
• ISA standards can be used in continuous, batch, and discrete
processes
31
The Role of P&ID’s in Project Success
• A P&ID is the single most important element in the drawing

package for:
– Defining and organizing a project

– Maintaining control over a contractor during construction
– Understanding how the plant is controlled after completion of the project
– Maintaining a record of what was intended and formally approved for
construction
– Recording what was constructed in the form of as- built P&IDs
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The Role of P&IDs in Project Success (cont’d)
• The P&IDs should define the exact scope of project

• P&IDs can be marked-up and highlighted to reflect the state
of a project at any point
• Diagrams must be a part of all change orders involving field
instruments, I/O points, equipment, or any other information
listed in any of the diagrams
• Changes to the P&ID must be transferred to the proper
schedule (instrument or I/O) to keep all project information
coordinated
33
The Role of P&IDs in Project Success (cont’d)
• When used for developing specifications, P&IDs are the

basis of agreement between plant and contractor
• P&IDs can define the contractor’s work
• If standard ISA conventions are followed, the definition is
understood by all parties
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P&ID Development
• Developed by many disciplines

• An interactive process
• Several revisions
• Active role in development
Production
Mechanical
Engineering
Electrical Piping
Instrumentation
35
Plot Plan
36
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Process Flow Diagram
• The Process Flow Diagram (PFD) defines the major

elements of the process schematically. It shows what
and how much of each product the plant will make, the
quantities and types of raw materials necessary to
make the products, what by-products are produced, the
critical process conditions—pressures, temperatures,
and flows—necessary to make the product, and the
major piping and equipment necessary.
37
Process Flow Diagram
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Binary Logic System
There usually is some on-off or binary or discrete control in a

continuous process. As the design progresses, the need to
define on-off control will become evident. For instance, on a
pulp and paper mill project, it may be necessary to isolate a
pump discharge to prevent pulp stock from dewatering in the
pipe if the pump is shut down. An on-off valve is added to
provide the isolation, but it is necessary to document why that
device was added and what it is supposed to do. Since this on-
off control may affect many design groups, it is important to
define.
39
Binary Logic System
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Instrument Location Plan
• Shows the location of field instruments

• Shows a simplified plan view of part of the plant with the
instrument location indicated by tag number and elevation
• Some designs:
– Do not duplicate instruments shown on piping or electrical plan drawings
– Show pneumatic and instrument air supply lines schematically and leave
exact routing and support to field installation crews
41
Instrument Location Plan (cont’d)
MATCH LINE TI - 001 MATCH LINE

DRG LP -1 DRG LP -3
TT - 007 EL - 121’ 0”
TE - 007
EL - 120’ 6”
FT - 001 FV - 001 FI - 101

EL - 101’ 6” EL - 102’ 0” EL - 104’ 6”
2” 150 CS” 008 E-1325.0

AS
2” 150 CS” 009 M
100 N-1500.0
AS
FT - 002 FV - 002 FI - 002 R-001
PLATFORM
EL - 101’ 6” EL - 102’ 0” EL - 104’ 6” ELEV
120’0”
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Loop Diagrams and Instrument Lists
• What is a loop diagram?

• Types of loop diagrams
• Loop diagram example
• What is an instrument list?
• Instrument list example
43
What is a Loop Diagram?
• A drawing, often 11 X 17 inches, that shows all devices in a

specific loop using symbolism and identifies the
interconnections
• In general, there is enough information on a loop diagram to
checkout or troubleshoot that loop
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Loop Diagrams Types and Uses
• Uses • Types
– Design – Pneumatic
– Construction – Electronic
– Start-up
– Operation
– Maintenance
– Modification
45
Loop Diagram
46 46
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What is an Instrument List?
The instrument list, or instrument index, is an alphanumeric

listing of all the devices or functions in a control system together
with various drawing and other references
47
Instrument List Example
Install
Tag # Description P&ID Spec # Loop Dwg Location Dwg Range
Detail
LI-50 VS. 50 H2S 103 L1 L-50 P-101 0-75" H2O D1
VS. 50 H2S - Low Level

LAL-50 103 L-50 0-10" H2O
Alarm
VS. 50 H2S - Low Level

LSLL-50 103 L2 L-50 P-101 0-5" H2O D2
Switch
LT-100 VS. 100 - K.O. Drum 103 L3 L-100 P-101 0-125" H2O D44
LI-100 VS. 100 - K.O. Drum 103 L4 L-100 P-101 0-100%
LT-201 VS. 201 - Distil. Column 205 L5 L-201 P-102 0-164" H2O D44
LIC-201 VS. 201 - Distil. Column 205 L-201 0-100%
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Instrument Data
Sheet
49
Specification Sheet 1
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Specification Sheet 2
51
P&ID Basic
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Control Loop on P & I Drawings
53
Cascade Control with required changes
Early stages of developing “As Built” Drawings
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As-Built Drawings
As-built drawings may have stamped approval and
marked as “As Built”!
55
29 CFR 1910.119- Management of Change
Management of change covers changes in process technology and

changes to equipment and instrumentation.
Changes in process technology can result from changes in

production rates
raw materials
experimentation
equipment unavailability
new equipment
new product development
change in catalyst
changes in operating conditions to improve yield or quality
Equipment changes include:

change in materials of construction
equipment specifications
piping pre-arrangements
experimental equipment
computer program revisions
changes in alarms and interlocks
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29 CFR 1910.119- Management of Change Continued
change includes all modifications to equipment, procedures, raw materials

and processing conditions other than ‘‘replacement in kind’’. These changes
need to be properly managed by identifying and reviewing them prior to
implementation of the change.
i.e. The operating procedures contain the operating parameters (pressure

limits, temperature ranges, flow rates, etc.) and the importance of operating
within these limits. Any operation outside of these parameters requires
review and approval by a written management of change procedure.
Employers need to establish means and methods to detect both technical

and mechanical changes and need to develop a form or clearance sheet to
facilitate the processing of changes through the management of change
procedures.
57
29 CFR 1910.119- - Management of Change SUMMARY
(1)The employer shall establish and implement written procedures to manage

changes
(except for ‘‘replacements in kind’’) to process chemicals, technology,
equipment,
and procedures; and, changes to facilities that affect a covered process.
(2)The procedures shall assure that the following considerations are addressed
prior to any change:
(i) The technical basis for the proposed change;
(ii) Impact of change on safety and health;
(iii) Modifications to operating procedures;
(iv) Necessary time period for the change; and,
(v) Authorization requirements for the proposed change.
(3) Employees involved in operating a process and maintenance and contract

employees whose job tasks will be affected by a change in the process shall
be informed of, and trained in, the change prior to start-up of the process or
affected part of the process.
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Week 3
Week 3
Certified Control
Course – Week 3
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© 2013
Standards
Certification
Publishing
8: Safety
© 2013, ISA
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NFPA 70E Table 130.7 (c)(11)
Risk Category determined by

Arc Flash Capability rated by:
• Calorie: The energy required to raise one gram of water one

degree Celsius at one atmosphere pressure. Second-degree
burns occur at 1.2 calories per centimeter squared per second (cal/cm2).
[energy]
• A Cigarette lighter placed under your finger for 1 second equals roughly a
1 calorie burn.
• A 100 cal/cm2 blast can reach temperatures of up to 35,000 degrees

Fahrenheit in the center, and 11,000 degrees on the perimeter
• Rule of thumb: Over 50 Volts requires gloves!
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Lockout / Tagout
NOTE: PERTAINS TO ALL ENERGY SOURCES,

PNEUMATIC, HYDRAULIC, MECHANICAL, ELECTRICAL
• Make necessary preparations for shut down.

• Shut down the machine or equipment.
• Turn off (open) the energy isolating device. (fuse/circuit
breaker)
• Apply the lockout-tagout device.
• Render safe all stored or residual energy.
• Verify the isolation and deenergization of the equipment
PPE (Personal Equipment Protection)
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9: Process Contamination/Decontamination
Material Safety Data Sheet
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4
Electrical Hazard Risk Category
• A classification of risk (from 0-4) defined by NFPA 70E.

Each category requires PPE and is related to incident
energy levels. (OSHA 29 CFR 1910.331 through .335)
ISA-84 and IEC 61511

SIS (Safety Instrumented System)
The primary function of a DCS or PLC is to hold specific process variables to

predetermined levels in a dynamic environment, while a SIS
is a static system Safety
Integrity
that takes action when a process is out of control and the
Level
control system is unable to operate within safe limits.
SIS – instrumented system used to implement one or more safety SIL 4

instrumented functions (SIF). A SIS is composed of any
combination of sensor(s), logic solver(s), and final element(s)”
SIL 3
SIL ..the Safety Integrity Level of a specific Safety Instrumented
Function (SIF) which is being implemented by a Safety
SIL 2
Instrumented System (SIS).
Risk: “the likelihood of a specified undesired event occurring within SIL 1

a specified period or in specified circumstances.”
10
© 2013, ISA
TS00E (v1.2)
5
ISA-84 and IEC 61511 Continued
Typical SIL 1 Design
11
Hazards
• Electrical Shock
– 0-1 mA Imperceptible
– 1-3 mA Perceptible
– 3-5 mA Annoyance
– 6-9 mA “no-let-go”
– 20 mA Asphyxiation
– 75 mA Ventricular fibrillation
– 4-10 A Cardiac Arrest, burns
• Electrical Energy Release Static-Stored
• Mechanical Hazards
• Heights and Accessibility
• Moving Equipment
• Eye Hazards
• Thermal Hazards
• Chemical Hazards
• LEL Hazards
• Etc.
12
© 2013, ISA
TS00E (v1.2)
6
Permits/Tags
• PPE
• Lockout-Tagout
• “Do Not Operate”
• Ready-to-Work
• Scaffold/Inspection
• Work Permit
• Safe or Cold Work Permit
• Hoy Work Permit
• Confined Entry-LEL
• Excavation Permit
• SIS
• Etc.
13
Installation in Hazardous Areas
• Hazardous area classification

– NEC class, division, group and zones
• Explosion confinement
– Explosion proofing
• Isolation of energy source
– Pressurization
– Purging
• Energy release limitation
– Intrinsic safety
– Nonincendive equipment
14
© 2013, ISA
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7
NEC Article 504
• Article 504 covers the installation of intrinsically safe apparatus in Class I, Class II, and Class III
locations (defined in Article 500.5) [504.1].
• An intrinsically safe circuit is one that won't ignite due to spark or thermal effect of (flammable or
combustible) material in air under prescribed test conditions [504.2].
• If it's part of an intrinsically safe installation, you must install it per the control drawing(s)
[504.10(A)].
• You can use a general enclosure with intrinsically safe apparatus [504.10(B)].
• You can use any of the wiring methods suitable for unclassified locations, when installing
intrinsically safe apparatus [504.20].
• You must separate intrinsically safe conductors from nonintrinsically safe conductors [504.30(A)].
This requirement is the core of Article 504 and its details make up about half of Article 504.
• You must connect intrinsically safe apparatus, enclosures, and raceways (if metallic) to the
equipment grounding conductor [504.50].
• Bond all metallic objects of an intrinsically safe system, per 250.100 [504.60]
• Enclosures that contain only intrinsically safe apparatus don't have to be sealed (except as
required by 501.15(F)(3)) [504.70].
• Intrinsically safe circuits must be identified at terminal and junction locations, in a manner that
prevents unintentional interference with the circuits during testing and servicing [504.80].
15
Hazardous Area Classification
• National Electrical Code (NEC) is sponsored by the National

Fire Protection Association (NFPA)
– Contains the most widely adopted set of electrical safety requirements

– NFPA 70 National Electric Code Article 500 Includes a classification
system consisting of three parts for hazardous areas where flammable
materials might be a problem:
– Class, Group, Division
– NFPA 70 National Electric Code Article 504 Includes codes for
Intrinsically Safe Systems
– NFPA 70 National Electric Code Article 505 Includes a classification for
Class 1, Zone 0, 1 and 2 Locations
16
© 2013, ISA
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Class Designations
• Class I
– Locations where flammable gases or vapors are or may be present in the
air in quantities sufficient to produce an explosive or ignitable mixture
(i.e., chemical plants and oil refineries)
• Class II
– Locations where combustible dusts may be present in sufficient quantity
to cause hazards (i.e., flour mills and coal pulverizing facilities)
• Class III
– Locations where the hazardous material consists of easily ignitable fibers
or flying's that are not normally in suspension in the air in quantities to
produce ignitable mixtures (i.e., sawmills and fiber manufacturing
facilities)
17
Class I Group Designations
• Group A
– Acetylene
• Group B
– Butadiene, ethylene oxide, propylene oxide, hydrogen (and gases or
vapors of equivalent hazard)
• Group C
– Cyclopropane, ethyl ether, ethylene, hydrogen sulfide (and gases or
vapors of equivalent hazard)
• Group D
– Acetone, alcohol, ammonia, benzene, butane, propylene, gasoline,
methane, natural gas (and gases or vapors of equivalent hazard)
18
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Class II Group Designations
• Group E
– Combustible metal dusts regardless of resistivity or other combustible
dusts of similar hazard (magnesium, aluminum, bronze powder, etc.)
• Group F
– Carbon black, charcoal, coal, or coke dusts that have more than 8
percent total volatile material
• Group G
– Combustible dusts (flour, starch, pulverized sugar and cocoa, dairy
powders, dried hay, etc.)
19
Division Designations
• Division 1
– The flammable or combustible mixture exists under normal conditions
(during regular maintenance activities, chemical releases that happen
regularly, etc.)
• Division 2
– The flammable or combustible mixture exists under abnormal
conditions (malfunctions, pipe rupture, equipment leaks, etc.)
20
© 2013, ISA
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10
Classification Practice
Finis
Area hing
ess able Area
c
Pro
a flamms Polyp
in ll time r
gas only opylene d
pylene tion at a unde
r abn ust is airb
Pro centra orma o
con l con rne
dition
s
POLYPROPYLENE PLANT
21
Imperial Sugar Dust Explosion Savanaha, GA
22
© 2013, ISA
TS00E (v1.2)
11
Fire and Explosion Components
For fire or explosion to occur,

triangle must be complete
To reduce hazard, eliminate the fuel, the oxidizer,

or the ignition source
23
Protection Techniques
• Explosion confinement
– Explosion proofing
• Isolation of energy source
– Pressurization
– Purging
• Energy release limitation
– Intrinsic safety
– Nonincendive equipment
Caution:
Decisions regarding
the safe installation of any
instrument is the responsibility
of an authorized design engineer
24
© 2013, ISA
TS00E (v1.2)
12
Explosion Confinement
EXPLOSIONPROOF
ENCLOSURE
CLASS I HAZARDOUS ATMOSPHERE
25
Pressurized Enclosures
NFPA 496 Standard for Purged and Pressurized Enclosures

Pressurization: The technique of guarding against the ingress of
the external atmosphere into an enclosure by maintaining a
PROTECTIVE GAS therein at a pressure above that of the
external atmosphere.
Purge Types:
X - reduces the classification within protected
enclosures from Division 1 to nonhazardous
Y - reduces the classification within protected
enclosures from Division 1 to Division 2
Z - reduces the classification within protected
enclosures from Division 2 to nonhazardous
Purging: In a pressurized enclosure, the operation of passing a quantity of

PROTECTIVE GAS through the enclosure and ducts, so that the concentration
of the explosive gas atmosphere is brought to a safe level
26
© 2013, ISA
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13
Intrinsic Safety
CONDUIT OR
HAZARDOUS OTHER
NONHAZARDOUS LOCATION
(CLASSIFIED LOCATION ENCLOSURE
CONTROL
ROOM
* EQUIPMENT
SEAL
I.S. TRANSMITTER
I.S. I.S.
SENSOR BARRIERS
SEAL ASSOCIATED
Apparatus
*
CONDUIT
I.S. TRANSMITTER OR OTHER
I.S.
SENSOR EXPLOSION PROOF ENCLOSURE
ENCLOSURE
SEALS
CONTROL
ROOM
* EQUIPMENT
I.S. TRANSMITTER EXPLOSION
I.S. BARRIERS PROOF
SENSOR CONDUIT
27
Device/Apparatus
• Simple apparatus
– Devices which will neither generate nor store more than 1.2 V; 0.1 A; 25
mW; 20 J
– Passive sensors (thermocouples, RTDs, contacts LEDs, etc.)
– Can be directly placed in hazardous locations
– No requirements for certification when connected to a certified barrier
• Intrinsically safe apparatus
– Devices in which all circuits are intrinsically safe

– Field instruments (transmitters, I/P, solenoid valves, etc.)
– Certification based on maximum energy level (group of gas) and
maximum surface temperature
28
© 2013, ISA
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Device/Apparatus (cont’d)
• Associated apparatus
– “An electrical apparatus in which there are intrinsically safe circuits

and non-intrinsically safe circuits. The latter can affect the safety
of the former.”
29
Shields
Shields. Where shielded conductors or cables are used,

shields shall be grounded
30
© 2013, ISA
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Shielded Cable/Ground Loop
31
Intrinsically Safe Barrier
NONHAZARDOUS AREA HAZARDOUS AREA
FUSE
+
CURRENT LIMITING
RESISTOR
FIELD
DEVICE
INPUT
d/p
XMITTER
FUSE DIODE
32
© 2013, ISA
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16
Installation and Maintenance Notes
• Initial and periodic inspections of intrinsically safe systems

are necessary
• Terminals in the control room that connect to the intrinsically

safe wiring should always remain covered unless the process
is shut down and the hazardous location is known to be
non-flammable
• Calibration signals should be injected on the non-hazardous

side of any intrinsic safety barrier, unless the calibration set
itself is intrinsically safe
33
Installation and Maintenance (cont’d)
• Replacement parts must be those specified by the

manufacturer - NO SUBSTITUTIONS
• Retain the integrity designed into the system by maintaining

the characteristics which made it intrinsically safe: grounding,
spacing of wires, types of insulation and selection of
electrical components
34
© 2013, ISA
TS00E (v1.2)
17
Nonincendive Equipment
• Equipment having electrical/electronic circuitry and

components that are incapable, under normal conditions, of
causing ignition of a specified flammable gas or vapor-in-air
mixture due to arcing or thermal effect
35
Basic Measurement Units
• Temperature
• Pressure
• Level
• Flow
36
© 2013, ISA
TS00E (v1.2)
18
Temperature Scale
37 37
Absolute/Atmospheric
Pressure Relationship
• PSIG
• PSIA
• PSI
38 38
© 2013, ISA
TS00E (v1.2)
19
Pressure and Level Measurement Units
True “level” is a measure of length. Inches water is a

pressure term. When a level measurement is made with a
pressure transmitter measuring inches of water, the
measure is hydrostatic head “pressure” not level
39
Atmospheric Pressure Limits
• The highest recorded atmospheric pressure, 108.57 kPa (1085.7 mbar or 32.06
inches of mercury), occurred at Tonsontsengel, Mongolia, 19 December 2001.
• The lowest sea level air pressure ever recorded was 870 mb (25.69 in.) in the eye
of Typhoon (Tip) over the Pacific Ocean, whereas the highest sea level air
pressure ever recorded was 1084 mb (32.01 in.) at Siberia associated with an
extremely cold air mass
• DO THE MATH
– 32.06 -25.69=6.37 inches of mercury
– 32.06 X .4911 =15.746 PSI
– 25.69 X .4911 =12.618 PSI
– 3.129 PSI Difference in atmospheric pressure
– Consider, the difference in absolute pressure 14.7 typical and the above
change in absolute!
– 14.7 PSI = 29.921” hg Typical
40
40
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Pascal’s Law
Pascal's law states that when there is an increase in pressure at any

point in a confined fluid, there is an equal increase at every other point
in the container.
P = F/A
P pressure
F force
A area
*the ratio of force is constant.

Brakes on a car are a good
example
41
41
Density
• Mass per unit of volume

• Grams per cu. cm
• Pounds per cu. ft.
– e.g. water = 62.4 lbs/ft3
– e.g. air = 0.076 lbs/ft3
– e.g. mercury = 848.6 lbs/ft3
42
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Specific Gravity
• Ratio of density of a process material to the density of

water or air
• Specific gravity of water = 1
Example:
Density (petroleum) = 54.8 lbs./cu. ft.
Specific Gravity =
• Specific gravity of air = 1

Example:
Molecular Weight of Gas = 44
Molecular Weight of Air = 29
Specific Gravity = 44/29 = 1.52
43
Viscosity
• Fluid property which affects its behavior

• The “flow ability” of a liquid or gas
• Gas viscosity is affected by pressure and temperature
• Liquid viscosity is affected by temperature
• Viscosity units commonly centipoise absolute viscosity
• Essential in selection and sizing of flow elements, e.g. orifice
plates, sizing pumps, agitators, pipe lines. Also in spraying,
dipping and coating
44
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Pressure of Fluids
45
Liquid Head Measurement
1 PSI = 27.72 in. wc

1 cu ft of water = 62.4 lbs
12' X 12" X 12"
Density of water = 62.4 LBS/CU FT
1 Square
inch
Pressure at bottom = Force/Area

(Force: 62.4 lbs)/(Area:144 Sq in) = 0.433 PSI per 12" wc
Or
0.433 PSI/12 = .03608 PSI per inch wc
46
© 2013, ISA
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23
Effect of S.G. on Liquid Head Measurement
• As specific gravity changes (& density changes) “h”, or head

must be multiplied by the specific gravity of the liquid to
convert to inches H2O
– This gives the pressure at the bottom of the tank in inches H2O
47
Unit Systems - Flow Measurement
gpm = gallons per minute

lbs/hr = lbs per hour
scfm = standard cubic feet per minute
scfh = standard cubic feet per hour
bpd = barrels per day
m3/hr = cubic meters per hour
kg/hr = kilograms per hour
48
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Flow Measurement of Fluids
• Liquids gpm, m3/hr, lbs/hr, bpd

• Gases scfm, scfh, m3/hr
• Steam lbs/hr, kg/hr
49
Flow Terms
Volumetric Flow - The volume of fluid that passes a point in the pipe per unit
of time:
Q = (A)(V)
WHERE: Q = volumetric flow rate (ft3/min)

A = cross-sectional area of pipe (ft2)
V = average fluid velocity (ft/min)
Mass Flow - Weight of of fluid flowing per unit of time:
M = (Q)(ρ)
WHERE: M = mass flow (pounds per minute)

Q = volumetric flow rate (ft3/min)
ρ = density (pounds per cubic foot)
50
© 2013, ISA
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25
Flow Terms
• Totalized flow = Accumulated flow = Integrated flow
• Turndown
– The ratio of the maximum flow that the flow meter can measure within
the stated accuracy (usually this is the full scale flow), to the minimum
flow can be measured within the stated accuracy
• Rangeability
– This is the measure of how much the range can be adjusted without
major modification. It is the ratio of the maximum full scale range to the
minimum full scale range of the flow meter
51
Conversion Table
52
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Conversion Table (Continued)
53
Conversion Table (Continued)
54
© 2013, ISA
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Conversion Tables
http://www.isa.org/ccst/CCST-
Conversions-document.pdf
Table 1 Multiples and Submultiples of SI Units
Table 2 Length Units
Table 3 Area Units
Table 4 Volume Units
Table 5 Mass Units
Table 6 Density Units
Table 7 Volumetric Liquid Flow Units
Table 8 Volumetric Gas Flow Units
Table 9 Mass Flow Units
Table 10 High Pressure Units
Table 11 Low Pressure Units
Table 12 Speed Units
Table 13 Torque Units
Table 14 Dynamic Viscosity Units
Table 15 Kinematic Viscosity Units
Table 16 Temperature Conversion Formulas
55
Today’s Objectives
• Fundamentals of Instruments
– Temperature
– Pressure
– Flow
– Level
– Analytical
• Final Control Elements
• Test Equipment
56
© 2013, ISA
TS00E (v1.2)
28
Week 4
Week 4
Certified Control
Course – Week 4
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Fundamentals of Instruments
• Devices
• Comparisons
• Installation considerations
© 2013, ISA
TS00E (v1.2)
1
Temperature Instrumentation
• Thermometers
• Bimetallic elements
• Thermocouples
• RTDs
• Thermistors
• Radiation pyrometers
Temperature
4 4
© 2013, ISA
TS00E (v1.2)
2
Glass Thermometer
5 5
Thermometer Styles
6 6
© 2013, ISA
TS00E (v1.2)
3
Thermometer
7 7
Bimetallic Thermometer
4 5 6
FREE END 3 7
FREE END
2 8
1 9
0 10
Rotating Shaft
HIGH
EXPANSION
COEFFICIENT
LOW Bulb Free End Attached

EXPANSION to Pointer Shaft
COEFFICIENT
FIXED END
FIXED END Fixed End
© 2013, ISA
TS00E (v1.2)
4
Thermocouples
The Seebeck effect is the conversion of temperature differences directly into electricity
Thermocouple Color Code
10
© 2013, ISA
TS00E (v1.2)
5
Various Thermocouple Assemblies
11
Thermocouple-2 dissimilar metals connected

together (Type “J”)
12 12
© 2013, ISA
TS00E (v1.2)
6
Thermocouple in Ice Bath (Type “K”)
13
13
3 wire RTD 100Ω 385 Alpha Standard
14
14
© 2013, ISA
TS00E (v1.2)
7
RTD Construction
15
Wheatstone bridge
An electrical circuit used to measure an unknown electrical

resistance by balancing two legs of a bridge circuit, one leg of
which includes the unknown component.
16
© 2013, ISA
TS00E (v1.2)
8
Industrial RTD’s
– 100 Ω Platinum @ 0oC

– 0.00385 Ω/ Ω/oC
– 0.00391 Ω/ Ω/oC
– 0.00392 Ω/ Ω/oC
– 0.003916 Ω/ Ω/o
– 120 Ω Nickel 0.00672 Ω/ Ω/oC
– 100 Ω Copper 0.00427 Ω/ Ω/ 25 oC (90.35 Ω @ 0oC)
– 10 Ω Copper 0.00427 Ω/ Ω/ 25 oC (9.035 Ω @ 0oC)
• There are other RTD”s such as the 500 ohm and 1000 ohm platinum RTD.
• As you can easily see from the short list that it is imperative that you know the
coefficient and its actual value at 0 degrees C.
17
RTD Calculation
In the event that you should need to approximate a
resistance value for a specific temperature or vice versa
while performing your troubleshooting procedure, you can
use the formula shown.
WARNING: Remember you must know the coefficient of

resistance and the exact value of the resistance at 0
degrees C.
RX is the unknown resistance

RB is the base resistance at 0 degrees C.
e.g. 100
α is the coefficient of resistance
T1 is the base temperature
T2 is the given or new temperature.
R x
 R 1   (T
b 2  T1 ) 
18
© 2013, ISA
TS00E (v1.2)
9
Thermistors
• Electrical resistance of material varies greatly with temperature

• Limited spans, low cost
• High accuracy and stability
• Limited to low-medium temps
19
Thermistor
20
20
© 2013, ISA
TS00E (v1.2)
10
RTD/TC/Thermistor Output
21 21
Immersion and Insertion Lengths
22
© 2013, ISA
TS00E (v1.2)
11
Radiation Pyrometers
23
Pressure
24
24
© 2013, ISA
TS00E (v1.2)
12
Filled Systems Capillary
25
25
Additional Mechanical sensing
26
26
© 2013, ISA
TS00E (v1.2)
13
Diaphragm Element
LEAD
WIRES CAPACITOR
PLATES
SENSING
DIAPHRAGM
RIGID INSULATION
SILICON
OIL
ISOLATING TOP VIEW SIDE VIEW

DIAPHRAGM WELDED SEALS
VARIABLE CAPACITOR SENSING MODULE
27
FLOW
28
28
© 2013, ISA
TS00E (v1.2)
14
Flow Instrumentation
• Open channel measurements

• Variable area flowmeters
• Magnetic flowmeters
• Vortex shedders
• Turbines
• Ultrasonic flowmeters
• Positive displacement flowmeters
• Differential pressure flowmeters
• Mass flowmeters
29
Flow
• Open Channel
– Weir’s and Flumes (you can see it, touch it)
• Closed Pipe
– Doppler, Mag Meter, Time of Flight, Vortex, Orifice Plate
Any time a flow is derived from a differential pressure the square

root has to be extracted
30
30
© 2013, ISA
TS00E (v1.2)
15
Open Channel Flow Measurement
• Weir
• Flume
• Require level measurement
• Usually used for large flows
– Waste treatment
– Rivers and streams
31
Parshall Flume
32
32
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16
Weir Contracted/Non-contracted
33
33
Rotameter Flow Meters
34
34
© 2013, ISA
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17
Velocity Meters (velocity measured, flow calculated)
Turbine
35
35
Mag-Meter
36
© 2013, ISA
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18
Vortex Shedding
37
Ultrasonic Flowmeter Principles
• Principle of operation
– Doppler
– Time of flight
• Construction
– Clamp-on transducer
– Wetted transducer
• Applications
– Large pipes
– Flashing fluids
– Corrosive fluids
– Hazardous fluids
– Non-coating service
38
© 2013, ISA
TS00E (v1.2)
19
Doppler/Time of Flight
Dopple Time of Flight

r
39
39
Positive displacement Flow meter
40
© 2013, ISA
TS00E (v1.2)
20
Differential Pressure
41
41
Orifice Taps
42
42
© 2013, ISA
TS00E (v1.2)
21
Concentric Orifice
THICKNESS OF THE PLATE

PIPE
UPSTREAM FACE DOWNSTREAM FACE
D d
=d
D
THICKNESS OF THE ORIFICE
(A)
D d
FLOW
DOWNSTREAM
EDGES
UPSTREAM
EDGE
NOTE: UPSTREAM EDGE VISUALLY DOES NOT

REFLECT A BEAM OF LIGHT.
(B)
43
Tap Locations in Orifice Plate
44
© 2013, ISA
TS00E (v1.2)
22
Orifice Plates
45
45
Orifice Installation
46 46
© 2013, ISA
TS00E (v1.2)
23
Venturi Flow Meter
47
47
Differential
Wedge Cone
Nozzle
48
© 2013, ISA
TS00E (v1.2)
24
Permanent Pressure Loss
49
49
Pitot Tube
50
50
© 2013, ISA
TS00E (v1.2)
25
Reynolds Number
What flow profile is best for velocity type flow measurement?

What is best for differential type?
What is best for positive displacement?
51
Reynolds Number
Reynolds number: A dimensionless criterion of the nature of flow in pipes. It

is proportional to the ratio of dynamic forces to viscous forces: the product of
diameter, velocity, and density, divided by absolute viscosity.
52
52
© 2013, ISA
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Reynolds’
Number
R = Reynolds’ Number
VDp V = Velocity
R= D = Pipe inside diameter
u
p = Fluid density
u = Liquid viscosity
53
53
Thermal Mass Flow Meter
54
© 2013, ISA
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27
Mass Flow Versus Volumetric
55
55
Coriolis Flow Meter-Mass Flow
56
56
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28
Coriolis Continued
57
57
LEVEL
58
58
© 2013, ISA
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29
Level / Inventory Measurement
WHERE
HOW
MUCH
How far from full

How far from empty
How much material
59
Level Instrumentation
• By surface detection
• By interface detection detecting the interface level between two liquids in the
same tank or vessel, such as oil and water. The dissimilar density or specific gravity of
the two liquids means the lower density liquid will float on top of the higher density liquid.
• By hydrostatic pressure
• By weight
60
© 2013, ISA
TS00E (v1.2)
30
Δ Pressure Transmitter
61
61
Tank Level Determine LRV/URV
62
62
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TS00E (v1.2)
31
Level Calculation-Open Tank
63
63
Level Calculation-Closed Tank
64
64
© 2013, ISA
TS00E (v1.2)
32
Level Calculation-Closed Tank WET
65
65
Span and Range Calculation Practice
System A System B
Zero Reference Suppressed Zero
Maximum Maximum
Sp. Gr. Sp. Gr.

1.2 2
20 In. 20 In.
Minimum Minimum
H L
2 In.
Vent H L
Vent
System C
Elevated Zero
Maximum
Wet
H20 Leg
20 In. Sp. Gr.
2
Minimum
H L
66
© 2013, ISA
TS00E (v1.2)
33
Remote Seal Differential Level Transmitter
67
Basic Sight Glasses
68
© 2013, ISA
TS00E (v1.2)
34
Dip Stick Level Measurement
CALIBRATEDGRADUATIONS
FORLEVELVALUES
69
Displacer
buoyancy force on an object is going to be equal to the weight of

the fluid displaced by the object
Archimedies
70
70
© 2013, ISA
TS00E (v1.2)
35
Volume of a Displacer
How much water is being displaced by the displacer?

Solve (πr² X amount the float is submerged in the liquid in inches)
What % of a cubic foot of water is now displaced?

Solve above answer / 1728 (number of cubic inches in a cubic foot)
Take this % times 62.4 (the weight of a cubic foot of water)
This is the amount of pressure on the force balance beam.
i.e. 6” displacer in 20” water

(3.1417 X 3 X 3 X 20) = 565.5
565.5 / 1728 = 32.7%
.372 X 62.4 = 20.405 lbs
71
71
Bubbler Level
72
72
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Capacitance Probe
73
Non Contact
Foam and water droplets on the face of the transducer are problems which may cause
LOE!
74
74
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Radar
Guided Wave, used

for interface issues
75
75
Radiation Point Measurement
76
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38
Rotating Paddle
77
Level Measurement by Weight
78
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39
Analysis Instrumentation
• PH
• ORP
• Conductivity
• Others
79
Analytical pH
80
80
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pH of Some Common Materials
81
Analytical pH
82
82
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Why Measure pH?
• As a measure of acidity or alkalinity

• To measure corrosion rate
• To measure water purity
• To neutralize wastes
• To measure process efficiencies
83
How pH is Measured
• Measuring electrode develops a potential directly related to

hydrogen ion concentration of solution
• Reference electrode serves as a constant reference
potential
• Change in voltage resulting from change in hydrogen ion
concentration is proportional to change in pH
84
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pH
• Acid rain, from auto exhaust or coal-fired power plants, causes a drop in the pH of water.
Pollution from accidental spills, agricultural runoff and sewer overflows can also change the
pH. Buffering capacity is water's ability to resist changes in pH, and is critical to the survival
of aquatic life. While young fish and insect larvae are sensitive to a low pH (acid), extreme
values on either end of the scale can be lethal to most organisms.
• Expected levels: 6.5 to 9.0
85
85
Analytical pH/ORP/Conductivity
pH: is
the logarithm
(base 10) of the
concentration of
dissolved
hydrogen ions.
86
86
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pH Sensor: Glass
87
Typical Problems
• Measuring electrode
– pH membrane coating
– Slow response due to high impedance
– Abrasion and/or breakage
– Temperature shock
88
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Typical Problems (cont’d)
• Reference electrode
– Plugging junction
– Poisoning of the internal element
– Rapid electrolyte depletion
– Ground Loops
89
© 2013, ISA
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45
Week 5 Week 5
Week 5
Certified Control
Course – Week 5
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
What is Oxygen Reduction Potential (ORP)?
• Potential is developed as a result of the transfer of electrons

• Electrode contains anode and cathode
• Oxidation (loss of electron) occurs at the anode
• Reduction (gain of electron) occurs at the cathode
• Potential is an indication of a reaction’s progress
© 2013, ISA
TS00E (v1.2)
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What is Conductivity
• Conductivity is the measurement of the ability of a solution

to carry an electric current
• It is a volume resistivity measurement determined by
applying an AC voltage across a primary element called a
cell immersed in a solution containing ions
Conductivity
• The conductivity of a solution is measured by determining the resistance of the

solution between two flat cylindrical electrodes separated by a fixed distance.
• Conductivity in water is affected by the presence of inorganic dissolved solids such as

chloride, sulfate, sodium, calcium and others.
• High conductance readings can also come from industrial pollution or urban runoff --
water running off of streets buildings, and parking lots. Extended dry periods and low
flow conditions also contribute to higher specific conductance readings. Temperature
also affects conductivity; warm water has a higher conductivity. Specific conductance
is measured in micro Siemens per centimeter (µs / cm).
4
4
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Conductivities of Ordinary Solutions at 25C
Specific
Resistance
100Meg 10Meg 1Meg 100K 10K 1K 100 10 ohm-cm
.01 .1 1 10 100 1000 10,000 100,000 1,000,000
Specific uS/cm
Conductance
3% NaOH
Very Pure Good Natural

Water Distilled 10% H2SO4
Waters
Water (Typical)
5
Dissolved Oxygen (DO)
The DO test measures the amount of oxygen dissolved in the

water. Oxygen is essential for both plants and animals, but high
levels in water can be harmful to fish and other aquatic
organisms. Nonpoint-source pollution can decrease the amount
of dissolved oxygen in water. The decomposition of leaf litter,
grass clippings, sewage, and runoff from feedlots decreases
DO readings. Decreased DO can be harmful to fish and other
aquatic organisms. Dissolved oxygen is measured in milligrams
per liter (mg/L). Expected levels: 4.0 to 12.0 mg/L
6 6
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Other Analysis Types
• Relative humidity
• Gas analysis/Gas Chromatography Sling Psychrometer
• Turbidity Wet/Dry Bulb
Relative Humidity
• Viscosity
Viscosity
7
Final Control Elements
© 2013, ISA
TS00E (v1.2)
4
Control Valves
• Control valve design

• Actuators
• Positioners
• Transducers
• Other final control elements
Valve Components (Air to ?)
10 10
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Valve Internal Components
11 11
Valve Flow Coefficient Cv
The flow coefficient of a device is a relative measure of its efficiency at allowing fluid flow.
It describes the relationship between the pressure drop across an orifice, valve or other
assembly and the corresponding flow rate.
Mathematically the flow coefficient can be expressed as:
where:
Cv = Flow coefficient or flow capacity rating of valve.
F = Rate of flow (US gallons per minute).
SG = Specific gravity of fluid (Water = 1).
ΔP = Pressure drop across valve (psi).
In more practical terms, the flow coefficient Cv is the
volume (in US gallons) of
water at 60°F that will flow per minute through a fully open valve with
a pressure drop of 1 psi across the valve.
12 12
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Characterized Valve Plugs
13 13
Characterized Valves
Quick Opening
Rapid increase in flow capacity when
valve begins to open
Rate of change decreases as travel
increases
Linear
Flow rate proportional to amount of
travel. Change in flow rate is constant
with valve travel
Modified Percentage (Modified
Parabolic)
Throttling action at low % opening
Almost linear after approximately first
20% of opening
Equal Percentage
Change in flow rate is always
proportional to the flow rate just before
the change in valve position is made.
Rate of change in flow increases with
increased travel. At low % opening, low
changes in flow rate. At high % opening,
high changes in flow rate
14 14
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Valves
15
Other Linear Motion Valves
16
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Rotary Motion Valves
Butterfly
Valve
Ball Valve
17
Cavitation
• A two stage phenomenon of liquid flow.
• The first stage: flashing

– the formation of voids or cavities within the liquid stream when the line
pressure falls below the vapor pressure of the liquid
• The second stage: cavitation

– the collapse or implosion of flashing cavities back into an all-liquid state
when the line pressure exceeds the vapor pressure
18
© 2013, ISA
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Actuators
19
I/P Transducer
• Used to convert current signal to pressure signal
Nozzle
Pressure
Filter Span
Exhaust
Restriction
W
3000 W
1500
300 150 W
500
500
Pilot Magnetic Coil 0Ω 0Ω Ω
Capacity
Tank
Output
Input
GAS
Rebalancing
Bellows Zero Adjustment
Nozzle Beam
20
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Diaphragm Principle
21
Direct (Air-to-Extend) ATC
22
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Reverse (Air-to-Retract) ATO
23
Actuator-Positioner-Valve
24 24
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Positioners
AIR
INSTRUMENT SIGNAL POSITIONER SUPPLY
ACTUATOR
VALVE STEM POSITION
BODY
25
Positioner-Why Use?
26 26
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13
Valve Positioner
Pneumatic
Positioner
DVC 6000
w/Diagnostics
27 27
Other Final Control Elements
• Dampers, vanes
• Pumps
– Metering
– Centrifugal
• Regulators
• Variable speed motors
• Variable frequency drives
28
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Other FCE’s
Position
Proportioning
Current
Proportioning
Time
Proportioning
29 29
Time Proportioning Control
30 30
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TS00E (v1.2)
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Test Equipment
Temperature:
RTD/Thermocouple/Thermometer
Beta, Martel, Dry Block Heater, Ice Bath, Fluke, Beamex, Kaye
Pressure
Vacuum/”WC/PSI
Beta, Ralston, US Gauge, Jofra, Ashcroft, Heise, Hand Pump
Flow
DP/Velocity/Proving
Secondary Standards
Level
Contact/non-contact
Ruler, many pressure items
Analytical
ORP/pH/Conductivity/etc
Buffer, test strip
Common items
Laptop, Communicator, Power Supply
31
Test and Calibration Equipment
• Hydraulic
– Deadweight tester
• Pneumatic
– Deadweight tester
– Manometer
– Packaged calibrators
• Electric/electronic
– Multimeter
– Electro-pneumatic calibrator
32
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High Pressure Calibration
33
“U” Tube Manometer
34
34
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U-Tube Manometers
35
U-Tube Manometers (cont’d)
36
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TS00E (v1.2)
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Manometer (Well Type)
Slant Tube
Manometer
37
37
Meniscus Effects
WATER MERCURY
38
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Pneumatic Calibrator
REGULATED
OUTPUT 2 INPUT
REGULATED
OUTPUT 1 TO BE
READ
AIR DIFF.
SUPPLY INPUT
P1 P3 S
P2
FILTER
REG. REG.
P1 P2
P3
VENT
39
DVOM (Digital Volt Ohm Meter)
40
40
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Documenting Process Calibrators
41
41
Secondary Standards
42
42
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Temperature Standard
43
43
• Calibration
• Instrument Performance
• Instrument Maintenance
• Troubleshooting
• Electrical Practices
• Advancing Technology
• Programmable Electronic System
• Ladder Logic Programming
44
© 2013, ISA
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22
Calibration
“a test during which known values of measurand are applied to a device and
corresponding output readings are recorded under specified conditions.” The
definition includes the capability to adjust the instrument to zero and to set the
desired span.
An interpretation of the definition would say that a calibration is a comparison of

measuring equipment against a standard instrument of higher accuracy to detect,
correlate, adjust, rectify and document the accuracy of the instrument being
compared.
(comparing a known to an unknown)
45
Calibration Classification
• Critical:
– An instrument, if non conforming to specification, could potentially compromise product.
• Non-Critical:
– An instrument whose function is not critical to product but is more of an operational
significance. i.e readings are obtained and recorded in operational logs.
• Reference Only (Convienence)

Not used for making quality decisions
Calibration frequency may require 6 month calibration for critical versus annual calibration
for non-critical.
OSHA, EPA, FDA, etc have requirements for these issues
46
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Out of Tolerance
• What happens:
– Questions, when did it go out of calibration?
– Answer: 1 microsecond after its last calibration, therefore, everything that

came in contact with this calibration is out of specs and must be
investigated/recalled, etc. The out-of-tolerance standard needs to
undergo reverse traceability of all calibrations performed since its last
known good calibration.
– The investigation must prove product quality was not affected or a

product recall, in the case of pharmaceutical, may be required.
– When billion dollar drugs are involved, this could devastate an

organization!
47
Calibration SOP
Pressure
SOP Number Title

SOP-CAL-PT01 Calibration/Calibration Check of Electronic Pressure Transmitter/Indicator
SOP-CAL-DPT-01 Calibration/Calibration Check of Electronic Differential Pressure Transmitter
SOP-CAL-DP03 Calibration of Differential Pressure Transmitter
SOP-CAL-V04 Calibration/Calibration Check of Pressure (Vacuum) Gauges
SOP-CAL-PS05 Calibration/Calibration Check of a Pressure Switch
Temperature
SOP Number Title

SOP-CAL-06 Calibration/Calibration Check of Temperature Indicator/Recorder
SOP-CAL-07 Calibration/Calibration Check of Dial Thermometer
SOP-CAL-08 Calibration/Calibration Check of RTD Input Electronic Temperature Transmitter
SOP-CAL-09 Calibration Check of Glass Thermometer
Level
SOP Number Title

SOP-CAL-10 Calibration/Calibration Check Differential Pressure Level Transmitter/Indicator
48
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SOP (Standard Operating Procedure)
49
Finding Standards
• Standards can be looked up at:
www.isa.org/findstandards
Enter the keyword and search available ISA standards.

Calibration/test equipment: ISA-82.03-1988
Loop Check: ANSI/ISA-62382-2012
SIS: ISA 84.01/IEC 61511
50
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Calibration Principles and Procedures
• Hierarchy of standards
• Three point calibration
check
• Five point calibration check
• Eleven point calibration
check
51
Calibration Block Diagram
52
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A Current Good Manufacturing Practice
A good rule of thumb is to ensure an accuracy ratio of 4:1

when performing calibrations. This means the instrument
or standard used should be four times more accurate than
the instrument undergoing calibration.
53
Hierarchy of Standards
• Instruments used as calibration standards are called test instruments

• Primary standard - test instrument against which the accuracy of all others
are compared (kept at NIST)
• Secondary standard - accuracy is directly traceable to primary standards
• Shop standard - accuracy is traceable to secondary standards
• All test instruments should be periodically certified
54
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Traceability
• Traceability: All calibrations should be performed traceable to a nationally

or internationally recognized standard. For example, in the United States,
the National Institute of Standards and Technology (NIST), formerly
National Bureau of Standards (NBS), maintains the nationally recognized
standards.
Traceability is defined by ANSI/NCSL Z540-1-1994 (which

replaced MIL-STD-45662A) as “the property of a result of a measurement
whereby it can be related to appropriate standards, generally national or
international standards, through an unbroken chain of comparisons.”
Note this does not mean a calibration shop needs to have its standards
calibrated with a primary standard. It means that the calibrations
performed are traceable to NIST through all the standards used to
calibrate the standards, no matter how many levels exist between the shop
and NIST.
55
Calibration Standards
56
56
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Uncertainty
57
Procedure
• January:
– Isotech TTI-22 and the temperature probe goes to Eastern Applied annually for
calibration and certification with all associated documentation.
• February/May/August/November:
– Fluke 744 is compared to the above equipment in a dry block heater quarterly with a
formal calibration/verification report filled out. Remember, this is only one function of
the many functions of the Fluke 744. This just proves the temperature calibration
aspect of this meter, still remaining is the voltage, current, resistance, etc. All
functions of the Fluke must have the paper trail to NIST and it must be current. If the
ball is dropped and the unit does not get shipped out for calibration, the entire system
falls apart. Any function used needs a trail to NIST
-Scenario: lets assume during the August verification you find the 744 is out of tolerance,
what are the implications? What do you have to do?
• Critical versus Non Critical
58
58
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Sample of Traceability
59
59
NIST Price Sheet 2011
60 60
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21 CFR part 11
Part 11 covers: All aspects of electronic records, including

signatures; integrity and authenticity; record creation; audit
trails; and archiving
Part 11 requires: Electronic records that are “created,

modified, maintained, archived, retrieved, or transmitted,
must be protected by procedures and controls to ensure
the authenticity, integrity and the confidentiality of
electronic records, and to ensure that the signer cannot
readily repudiate the document as not genuine.”
61
Documentation CFR 21
• Appropriate controls over system documentation including access to
documentation for system operation and revision and change control
procedures that documents time-based system modification.
Master Control is a closed system that requires an ID and password to
access any information. This information is controlled by privilege. Master
Control also comes with built in revision and change control capabilities.
• Determination that persons using the electronic system have been properly
trained to perform their assigned tasks.
Master Control provides comprehensive product training program. Training
courses are given for each level of user to ensure that every user can
perform assigned tasks within the Master Control system.
• Electronic signatures and handwritten signatures executed to electronic

records shall be linked to their respective electronic records.
Every signature is linked to a specific record. The signature information
cannot be tampered with after approval.
62
62
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Source/Simulate
63
Three-Point Calibration Check
• The three point calibration checks the LRV, Mid-Point and the
URV of the devices specified range.
• Test points are: 0%, 50% and 100% of range
• Currently there is no standard that mandates the number of

calibration points that must be checked
64
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Five-Point Calibration Check
• A credible calibration should include five points of reference:
Test Points: 0%, 25%, 50%, 75%,100%
• Should include upscale and downscale checks to detect

hysteresis, repeatability and reproducibility errors
65
Verification: Without Adjustment
• Verification that a non-adjustable device is performing as

accurately (error free) as necessary for the process
requirements
– Thermocouples
– RTDs
– Non-adjustable gauges and indicators
66
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Math (% method)
In the case of pneumatic, substitute 16 mA with 12 PSI and 4 mA with 3

PSI
67 67
Calibration Form
Possible Required Information:

Calibration Equipment Used
When it was calibrated.
When it is due.
S.O.P Reference-date-rev
Calibration as found
Calibration inputs increasing
Calibration inputs decreasing
As Found
As left
% Error
Within tolerance-no adjustment
Within tolerance-adjustments made
Out of Tolerance--Notification Sign-off
Technician Signature
Calibration Date
ETC
68
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Calibration Chart
69
Calibration Example 1 (Chart)
70
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Calibration Example 1 (As Found Error)
71
Calibration/Status Stickers
72
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Week 6 Week 6 Week 6 Week 6 Week 6
Week 6
Certified Control
Course – Week 6
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Instrument Performance
• Range and span

• Suppressed/elevated zero
• Accuracy
• Repeatability
• Reproducibility
• Linearity
• Hysteresis and dead band
• Instrument errors
• Tolerance
© 2013, ISA
TS00E (v1.2)
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Range-Span-EU-mA Relationship
3 3
Range and Span (cont’d)
• Range
– The region between the limits within which a quantity is measured,
received, or transmitted, expressed by stating the lower and upper
range values
• LRV (lower range value)
– Lowest value of the measured variable that a device is adjusted
to measure
• URV (upper range value)
– Highest value of the measured variable that a device is adjusted
to measure
• Span
– Algebraic difference between the upper and lower range values
Linearity
– The closeness to which a curve approximates a straight line
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Suppressed and Elevated Zero Range
• Suppressed-zero range
– A range in which the zero value of the measured variable is less than the
lower-range value
• Elevated zero range
– A range in which the zero value of the measured variable, measured

signal, etc., is greater than the lower range-value
– simply ask yourself where zero is, is it above or below the Lower Range
Value, if zero is above LRV, you have an elevated zero
Range and Span Terminology
© 2013, ISA
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Turn Down (Rangeability)
7 7
Error
• The algebraic difference between the indicated and the

actual values of the measured variable
– Span error
– Zero error
– Linearity error
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Zero Error
Green Line is ideal value
9 9
Span Error
10 10
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Zero & Span Error
11 11
Nonlinearity
12 12
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Linearity
Linearity: defined as
the closeness to
which a curve
approximates a
straight line.
13
Linearity Error
14
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Hysteresis and Dead Band (cont’d)
Hysteresis - the measure of the

difference in response of a
device or system as the input
signal increases from a minimum
value to a maximum value, and,
subsequently decreases from
maximum to minimum over the
same range
Dead band - occurs when the

output of a device does not
immediately respond to an input
change if direction is reversed
15
Accuracy
Accuracy: the degree

of agreement between
a measured, indicated or
recorded value and a
recognized or accepted
standard; usually
expressed as a
percentage of
measurement, span or
full scale value
16
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Repeatability/Reproducibility
Repeatability:
is the closeness
of agreement
among a number
of consecutive
measurements of
the output for the
same value of
the input under
the same
operating
conditions and
approaching
from one
direction.
17
Importance of Accuracy
18
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Tolerance
Tolerance: Permissible deviation from a specified value; may be

expressed in measurement units, percent of span, or percent of
reading.
For example, you are assigned to perform the calibration of a 0-to-300 psig pressure
transmitter with a specified calibration tolerance of ±2 psig. The output tolerance
would be:
– 2 psig
– ÷ 300 psig
– × 16 mA
– 0.1067 mA
The calculated tolerance is rounded down to 0.10 mA, because rounding to 0.11 mA
would exceed the calculated tolerance. It is recommended that both ±2 psig and
±0.10 mA tolerances appear on the calibration data sheet if the remote indications
and output milliamp signal are recorded.
19
Performance Specifications (Example)
• Accuracy Rating
–  0.2% of calibrated span

– Includes combined effects of the following
– Repeatability
– Linearity
– Hysteresis
– Dead band
– None
20
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Instrument Maintenance
• Definition
• Importance
• Types
21
Maintenance Defined
• Knowledge and skills needed

• Importance of good maintenance
– Maintenance strategy is becoming an important topic because of aging
systems in developed countries and the lack of experienced personnel in
all areas of the world. The goal of a maintenance strategy is to achieve
the highest automation system availability consistent with the
organization’s safety, capital investment and profit goals. Availability is
defined as how often the system is operationally available for use and
functioning correctly. When the system is not 100% available, production
profits are lost. What is the best way to achieve higher availability?
Corrective maintenance
• Preventive maintenance
• Predictive maintenance
• Troubleshooting
22
22
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What is Instrument Maintenance?
Actions taken to keep an instrument system fully operational

and/or restore a system to operation after a system failure:
– Corrective / Reactive
– Preventive
– Predictive
Instrumentation and control systems include many types of

equipment:
– Mechanical and pneumatic

– Electrical and electronic
– Computer and communications
23
23
Knowledge and Skills for Maintenance?
An understanding of processes and knowledge of control

systems strategies
Skills to install, troubleshoot, maintain, calibrate, and repair

systems and equipment:
– Mechanical and pneumatic

– Electrical and electronic
– Computer and communications
24
24
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Importance of Good Maintenance
• Ensures product quality

• Increases production efficiency
• Reduces mean time to repair (MTTR) and extends mean
time between failures (MTBF)
• Enhances a safe working environment for employees
and the public
• Good maintenance includes all three types:
– Corrective
– Preventive
– Predictive
25
25
Corrective Maintenance
Corrective Maintenance: Maintenance that is specifically
intended to eliminate an existing fault. Synonymous
with emergency maintenance. Contrast with preventive
maintenance.
Unscheduled or emergency maintenance in response to a

system/component degradation or failure (affects
productivity)
All devices must be repaired and restored to service in the

quickest time following failure or malfunction
Usually occurs when environmental conditions, personnel

capabilities, and necessary equipment are in less than
optimal readiness
May include troubleshooting, repair, replacement,

calibration, etc.
26
26
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Preventive Maintenance
• Scheduled maintenance that is planned, with

materials on hand, personnel on site, and
production planning advised
• Intended to prevent faults from occurring during

future operations
• May occur hourly, daily, weekly, monthly,

annually or at some other logical, practical
interval
• Must be able to take equipment out of service
27
27
Predictive Maintenance
• A maintenance program to anticipate

when failure is going to or about to occur
– Vibration analysis
– Noise
– Oil samples
– Temperature analysis
• When predictive maintenance practices

indicate an upcoming problem, preventive
maintenance can be scheduled to avoid
system/component failure
28
28
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Summary: Maintenance Defined
Knowledge and skills needed

Importance of good maintenance
– Corrective maintenance
– Preventive maintenance
– Predictive maintenance
Troubleshooting
29
29
Troubleshooting
• Troubleshooting is a method used to identify and correct a

problem that should incorporate a logical step-by-step
approach ot quickly and economically resolve the problem.
– Verify that a problem exists

– Identify and locate the cause of the trouble
– Repair or fix the problem
– Test to see if the problem has been corrected
– Follow up to eliminate future problems
30
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Troubleshooting Resources
• Manuals
• Fellow Technicians
• Maintenance Management Systems
• Vendor Technical Assistance
• Direct Vendor Access
• Maint Contracts
31
RCA (Root Cause Analysis)
A logical structured process used to find the cause of a

problem.
Metaphor: each link of a chain is dependent on the previous

link. (X and Y must be true to have Z True)
Another metaphor: like taking down a tree from the top down,
you remove the branches one at a time to get to the main
trunk.
32
© 2013, ISA
TS00E (v1.2)
16
Failure
• Something's are designed with a failure in mind,

FC Valve (fail close)
FO Valve (fail open)
FLS (Fail last state)
AFO (air fail open)
Up scale Burn Out (thermocouple)
Part of the SIS technology
33
Why Troubleshoot?
• Something is not functioning properly

• You do not know what is wrong
• Equipment is down
• Product is out of specifications
• Inconsistent measurement
34
© 2013, ISA
TS00E (v1.2)
17
Purpose of Troubleshooting
• Maximize safety
• Minimize down time
• Maintain/Improve plant efficiency
• Maintain/Improve product quality
35
What Are You Expected to Troubleshoot?
• Process • Concentration
• Loop • Conductivity
• Device • Density
• Board or module • Dew Point
• Discrete • Flow
• components • Humidity
• Pneumatic • Level
equipment • Position
• Electronic • Pressure
equipment • Temperature
• Digital systems • Vacuum
• Analytical systems • ETC
• Computers
• Color
36
© 2013, ISA
TS00E (v1.2)
18
Troubleshooting
How many feel effective troubleshooting is a natural

talent or is it a learned skill?
– Discussion
– Deck of Cards
– Conclusion
37
37
Don’t you wish it were this simple
38
38
© 2013, ISA
TS00E (v1.2)
19
Troubleshooting Skills
• Time
• Tools
• Talent
• Training
39
Troubleshooting Productivity
• Dependent upon:
– What your equipment consists of

– What test equipment you have
– Your company’s philosophy
– What parts you have available
– What time frame you have
– Your level of expertise
40
© 2013, ISA
TS00E (v1.2)
20
Troubleshooting Considerations
• Purpose
• Skills
• Approaches
• Logical Analysis
41
Troubleshooting
Troubleshooting considerations
Psychology:
– Does this problem cause the operator to work harder as a result of the
problem?
– Did the problem start at the end of a shift ?
– Is there a feud between operators on different shifts?
– Are there labor relations problems in the plant?
Unfortunate but true, you must prove there is a legitimate failure or problem!
42
© 2013, ISA
TS00E (v1.2)
21
Approaches to Troubleshooting
• Logical Analysis
• Input/output (serial)
• Halving approach
• Equipment history
• Shotgun approach
43
Logical Analysis Method Flowchart
1: Define the problem
2: Collect Information about the problem
3: Analyze the information
4: Determine the Sufficiency of Information
5: Propose a solution
6: Test the Proposed Solution
7: Repair
If the problem is not resolved begin reiteration of the steps

until the problem is found and resolved.
If the problem is resolved; document. Store/file and send to

the appropriate department for follow up.
44
© 2013, ISA
TS00E (v1.2)
22
Identify and define the problem
• Ask the operator

• Talk to supervision
• Observe the process behavior
• Make sure you understand how it is supposed to function when
operating properly
• Make sure you understand the associated equipment and how
it can influence the operation of the suspect equipment
45
Gather information and data about the problem
• Review the equipment history file

• Review the manuals
• Review trend records
• Review graphics and alarms
• Review P&IDs and loop drawings
• If it is technical in nature: look at the specifications
• Ask your fellow technicians if they have had a similar problem
46
© 2013, ISA
TS00E (v1.2)
23
Input/output (Serial) Approach
• Trace signal through loop or equipment

• Start at one end and work through system checking the signal
in and out of different devices until the problem is located
• Advantages
– It works in all systems
– It requires you to be familiar with the system
– Other advantages
• Disadvantages
– It can be very slow. Suppose it is the valve causing the problem?
– Other disadvantages
47
Input/output Approach
Start with the sensor then work through each element of the
loop to determine the source of the problem
48
© 2013, ISA
TS00E (v1.2)
24
Halving Approach
• Use the divide and conquer technique of input/output testing

with this system:
A-> B-> C-> D-> E-> F-> G-> H

• With system operational:
– Test D input/output
If good, then A,B,C are good too
– Test G input/output
If good, then E and F are good too
H must be the problem
• This minimizes the number of checks that have to be made,

saves time
49
Equipment History Approach
• Look for the problem based on past experiences

– Recognize symptoms
– Be familiar with equipment and plant
– Recognize similar responses from similar problems with
different equipment
– Can be used from component level to control systems
• Advantages
– Familiar problems can be quickly solved
– Other advantages
50
© 2013, ISA
TS00E (v1.2)
25
Equipment History Approach (cont'd)
• Disadvantages
– May waste valuable time

– Difficult to apply to unfamiliar equipment or systems
– Other disadvantages
51
Shotgun Approach
• No real rhyme or reason

• Requires very little skill
• Hit or miss
• Advantages?
• Disadvantages?
– Least efficient
– Should not be used
– Not systematic
– Trademark of an untrained
technician
52
© 2013, ISA
TS00E (v1.2)
26
Other Methods: “Whatever it Takes”
• Substitution: replace with known Good

• Fault Insertion: Insert a fault and observe
• Remove and Conquer: Remove components
• Trapping: Timing issues
• Complex to Simple: Break down the complexity
• Consultation: Third Head Technique
• Intuition: Go with you gut
53
Troubleshooting with DCS
• Elements
• Graphic display
• Trend display
• Alarm summary
• Problem identification
54
© 2013, ISA
TS00E (v1.2)
27
Distributed Control System
55
Elements of a Distributed Control System
• Central control console

– Keyboard
– Display screen
– Graphic display
– Trend graph display
– Alarm summaries
• Data highway
• Microprocessor-based controllers
• Process units
56
© 2013, ISA
TS00E (v1.2)
28
DCS Graphic Display
FT
101
ABV
100% CLOSED
FLOW
SP 0%
PV -25%
FT
102
ABV
100% CLOSED
FLOW
SP 0%
PV -25%
PT
103
100%
FLOW
TEMPERATURE SP 0%
TT
SP 0% PV -25%
301
PV -25%
57
DCS Trend Display
58
© 2013, ISA
TS00E (v1.2)
29
DCS Alarm Summary
59
Bottom Line
• Minimize unscheduled downtime

• Product running at specifications
• All instruments operating properly
• Minimize troubleshooting time
• Essential ingredient
– Good preventive maintenance program
60
© 2013, ISA
TS00E (v1.2)
30
Basic Electric Diagram
61
Current Loop Characteristics
• How a series current loop works
• Constant current source
• Ohm’s Law
• Calculating maximum loop resistance
62 62
© 2013, ISA
TS00E (v1.2)
31
Ohm’s Law
63 63
Electrical Formulas Practice
RT =
RT =
64
© 2013, ISA
TS00E (v1.2)
32
Resistance Measurement
65 65
Resistor Color Code
66 66
© 2013, ISA
TS00E (v1.2)
33
Current to Voltage Conversion (review)
67 67
Voltage Measurement
68 68
© 2013, ISA
TS00E (v1.2)
34
Current Measurement
69 69
DO NOT Measure Voltage in Current Mode
Many companies do not

measure more than 30 V
with very expensive
multifunction calibrators.
This will at minimum
blow a internal fuse and
very well may damage
the meter to the point of
factory repair or
replacement.
70
© 2013, ISA
TS00E (v1.2)
35
Control Loop
71 71
Terminations/Splices
72
© 2013, ISA
TS00E (v1.2)
36
Typical Instrument Wiring
73
Loop Wiring Practice
74 74
© 2013, ISA
TS00E (v1.2)
37
Week 7
Certified Control
Course – Week 7
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Advancing Technology
• Current practice
• Industry’s changing needs
• Benefits and disadvantages
• Functions
© 2013, ISA
TS00E (v1.2)
1
Standard Practice
HART (FSK) Operation
The HART Protocol communicates at 1200 bps
© 2013, ISA
TS00E (v1.2)
2
Smart Transmitter Operation
PROCESS ZERO POT

PRESSURE
SIGNAL OUTPUT 4-20 mA

SENSOR
CONDITIONING CONDITIONING OUTPUT
ANALOG TRANSMITTER SPAN POT
PROCESS
PRESSURE MEMORY
4-20 mA
SENSOR A/D MICROPROCESSOR D/A
OUTPUT
SMART TRANSMITTER DIGITAL

COMMUNICATIONS
Analog to Digital Conversion
© 2013, ISA
TS00E (v1.2)
3
Digitizing a Measurement
EXAMPLE:
4-20 mA represents 0-2500º
16 mA span/2500 (EU)
engineering units=.006 mA
per degree. This defines the
resolution of the signal that
is digitized. This is a 14 bit
register, the more bits of
resolution , the more the
digital signal replicates the
analog, with the appropriate
sample rate!
Industry’s Changing Needs
• Better accuracy
• Better repeatability
• Better linearity
• Better communications
• Better reliability
• Better ability to adapt to process changes
• Less expensive physical plant (wires) both in initial cost and
lifetime costs
© 2013, ISA
TS00E (v1.2)
4
Smart Transmitters
• Better accuracy
– + 0.1% of span (smart) versus + 0.2% of span (analog)
• Linearity
– No hysteresis, linearity is curve and temperature compensated (it is nice
to have a microprocessor to perform a convenient algorithm)
• Better rangeability
– 30 to 1 compared to 5 to 1
• Reliability
– Mean time Between Failures (electronics only) exceeds (typically) 50,000
Hrs
• Diagnostics
– The ability to access standard Instrument internal diagnostics and
locate/identify problems
HART Protocol
10
10
© 2013, ISA
TS00E (v1.2)
5
Smart Devices
11
HART Smart Communicators
12
12
© 2013, ISA
TS00E (v1.2)
6
The Microprocessor
• Smart transmitters contain a microprocessor that can improve

sensor performance and or access to remote communications
through a hand-held interface device, control system, or both
• The microprocessor improves sensor performance in two
ways
– First, it can store input/output curves to compensate for sensor output
errors caused by factors outside the process
– Second, it can perform math calculations that condition the
sensor output
13
The Microprocessor (cont’d)
• The microprocessor can also improve the performance of

an average or below average sensor by characterization
• One limiting factor is the update rate of the microprocessor
– The best variables to characterize are ones that change at a relatively

slow rate
– Faster microprocessors require more power (and dissipate more heat)
14
© 2013, ISA
TS00E (v1.2)
7
Smart Instrument Characterization
• Characterization involves matching the sensor and transmitter
– This is done using high accuracy standards (temp, pressure etc.) for
calibrating the sensor and transmitter as one
– The microprocessor in the transmitter is used to store calibration data
points and compensate for any non linearity's
– This makes for a very accurate instrument
15
Characterization and Digital Trim
16
© 2013, ISA
TS00E (v1.2)
8
Smart Transmitter Functions
• Self diagnostics
• Sensor temperature compensation providing improved
linearization
• Remotely programmable zero and span
• Output options:
– Linear
– Square root
– Percent
• Capable of measuring more than one process variable (e.g.,
mass flow)
17
Configuration vs. Calibration
18
© 2013, ISA
TS00E (v1.2)
9
Reranging
19
Loop Checking
• Smart devices makes loop checking more efficient, “loop

test mode” allows tech to input various signals to drive the
system components thus allowing system checkout
20
© 2013, ISA
TS00E (v1.2)
10
Programmable Electronic Systems
• Numbering systems
– Decimal
– Binary
– Octal
– Hexadecimal
• Basic PLC system
– Ladder logic
21
Basic PLC System
22
© 2013, ISA
TS00E (v1.2)
11
Numbering Systems
• Decimal numbering system

• Binary numbering system
• Octal numbering system
• Hexadecimal numbering system
23
Decimal Number
24
© 2013, ISA
TS00E (v1.2)
12
Binary Number
A binary number, N2 , can be written as:
N2 = bn2n + ... b222 + b121 + b020

b is the binary digit and can assume values of 0 and 1
Example:
10101 = 1 x 24 + 0 x 23 + 1 x 22 + 0 x 21 + 1 x 20
= 1 x 16 + 0 x 8 + 1 x 4 + 0 x 2 + 1 x 1
= 16 + 0 +4+0 +1
= 21 (decimal)
25
Octal Number
An octal number, N8 , can be written as:
N8 = on8n + ... o282 + o181 + o080
o is the octal digit and can assume values of 0, 1, 2, 3, 4, 5, 6, 7
Example:
13018 = 1 x 83 + 3 x 82 + 0 x 81 + 1 x 80
= 1 x 512 + 3 x 64 + 0 x 8 + 1 x 1
= 512 + 192 +0 +1
= 705 (decimal)
26
© 2013, ISA
TS00E (v1.2)
13
Hexadecimal Number
A hexadecimal number, N16 , can be written as:
N16 = HnRn + ... H2R2 + H1R1 + H0R0
H is the hexadecimal digit with values of 0 through 9 and the

letter A, B, C, D, E and F
The radix, R is equal to 16 in the hexadecimal system
Example: 8AE16 = 2222 (decimal)
27
Compare
28
© 2013, ISA
TS00E (v1.2)
14
Conversion Practice
• Binary and octal numbers
– A. Convert the binary number 101110 to its decimal equivalent

– B. Convert the octal number 257 to its decimal equivalent
29
Ladder Logic Programming
• Typical ladder logic format

• Ladder logic instructions
• Input/output wiring diagrams
30
© 2013, ISA
TS00E (v1.2)
15
Ladder Diagram / Logic Conversion
And, Nand, Or, Nor
31 31
Typical Ladder Logic Format
32
© 2013, ISA
TS00E (v1.2)
16
Relay Type Instructions
33
Start/Stop Ladder Logic
34
© 2013, ISA
TS00E (v1.2)
17
Input Wiring Diagram
35
Output Wiring Diagram
36
© 2013, ISA
TS00E (v1.2)
18
PLC
37
37
Electrical Drawings
38 38
© 2013, ISA
TS00E (v1.2)
19
SCADA Supervisory Control and Data Acquisition
39
39
• Fieldbuses
• Process Dynamics
• Controller Actions and Modes
• Control Modes
• Tuning Modes
• Advanced Control Strategies
• Instrument Installation
• Start-Up Concerns
• Loop Checking
• Maintenance Management
• CCST Exam Overview
40
© 2013, ISA
TS00E (v1.2)
20
Fieldbus
• Definition
• Fieldbuses
– Hierarchy
– Why fieldbus?
• Foundation Fieldbus
– H1
– Device Descriptions
– HSE
41
Fieldbus Definition
• Two or more addressable field devices which are electrically

connected using digital signaling techniques, and utilizing
either a shared media or media switches
• It places control and control strategies at the measurement or
control locations in the field
42
© 2013, ISA
TS00E (v1.2)
21
What is a Fieldbus?
• A field or device bus is a digital, two-way, communications link

for intelligent field devices
• Based on multi-point wiring technologies
43
Bus Hierarchy
• Most experts divide the

field/device networks
into 3 hierarchies:
– Full Service Control Buses
(e.g. FF, PROFIBUS)
– Device Buses
(e.g. DeviceNet)
– Bit-Level Sensorbuses
(e.g. Seriplex, AS-i)
44
© 2013, ISA
TS00E (v1.2)
22
Networks
45
Why Use a Fieldbus?
• Advantages:
– Less field wire, junction boxes and marshaling cabinets
– More data available from the field device
– Faster engineering, installation and commissioning
– Improved predictive maintenance
– Reduced long term maintenance
• Disadvantages:
– New technology requires new skills
– Learning curve may slow projects at first
46
© 2013, ISA
TS00E (v1.2)
23
Foundation Fieldbus H1 Bus Segment
9-32 Vdc H1 DC power signal Host H1 Cards
Power Supply conditioner module
H1 Bus Trunk
Field Device
H1 Bus Spur H1 Bus Terminator
47
Device Descriptions
Device from
Vendor A
Device descriptions
Device from
Vendor B
H1 Fieldbus
Host
Allow operation of devices from the host with only one version
of a human interface program, so everything looks and feels
the same to the operator
48
© 2013, ISA
TS00E (v1.2)
24
Foundation Fieldbus HSE Network (cont’d)
Automation
and
Display Systems
Windows PC
HSE Network
PLC HSE Network HSE Network
100 Mbits/s
or 100 Mbits/s 100 Mbits/s
DCS HSE Switch/Router
HSE Linking Device

H1 Network H1 Network
31.25 kbits/s 31.25 kbits/s
P P
L L
F F
49
Fieldbus Summary Slide
• Definition
• Fieldbuses
– Hierarchy
– Why fieldbus?
• Foundation Fieldbus
– H1
– Device Descriptions
– HSE
50
© 2013, ISA
TS00E (v1.2)
25
Process Dynamics (Response to Change)
51
Dead Time
52 52
© 2013, ISA
TS00E (v1.2)
26
First Order Lag
53
Controller Actions and Modes
• Direct and reverse actions

• On-Off control
• Proportional control
• Integral control
• Derivative control
54
© 2013, ISA
TS00E (v1.2)
27
Control Hierarchy
Scheduling and Other

Corporate Level Controls
Optimization
Advanced Regulatory Control

( Ratio, Cascade, Feedforward )
Basic Regulatory Control

( Feedback )
Safety Controls
Process
55
On-Off Control of Heating
56
© 2013, ISA
TS00E (v1.2)
28
Controllers and Control Strategies
Disturbances
Controller Output
Final
Algorithm Control
Set Point  (Control Law) Process
Element
Process
Measurement
57
PID Compromise
58 58
© 2013, ISA
TS00E (v1.2)
29
Direct Acting Controller
59
Reverse Acting Controller
60
© 2013, ISA
TS00E (v1.2)
30
Direct or Reverse Acting ?
61
Direct or Reverse Acting ?
62
© 2013, ISA
TS00E (v1.2)
31
Controller Modes
Proportional control action A corrective action that is proportional to the error.
PI control “Proportional-plus-integral control. Two types of control that are

used in combination to eliminate offset.
PID control “Proportional-plus-integral plus-derivative control.” Used in

processes where the controlled variable is affected by long lag times.
63 63
Proportional Action
• Proportional band
– Percentage of process error that will produce 100% output
change
– Always expressed as a percentage
• Gain
– A dimensionless number that defines the ratio of the change in
output, due to proportional control action, to the change in input
64
© 2013, ISA
TS00E (v1.2)
32
Gain/Proportional Band
65 65
Proportional Control
66
© 2013, ISA
TS00E (v1.2)
33
Offset
67 67
Offset with Proportional Control
100¡
Offset
90¡
80¡
70¡ Load
Change
60¡
68
© 2013, ISA
TS00E (v1.2)
34
Integral Action
• Integral (reset):
•
– Control action in which the output is proportional to the time integral of the
error
– Integral/Reset action is adjusted in minutes/repeat or repeats/minute
Minutes/Repeat Repeats/Minute
2.0 0.5
1.0 1.0
0.5 2.0
69
Proportional + Integral Control
70
© 2013, ISA
TS00E (v1.2)
35
Integral Control
PROPORTIONAL
ACTION SET POINT
ONLY
TIME
PROPORTIONAL SET POINT

PLUS
INTEGRAL
TIME
71
Function of Gain/Integral
72 72
© 2013, ISA
TS00E (v1.2)
36
Derivative Action
• Derivative (rate):
– Control action in which the output is proportional to the rate of change in
the error
– Derivative action is adjusted in minutes
• Used for processes with slow response or long time lags
• Can reduce overshoots which cause problems
• Not used on fast or noisy loops
73
Derivative (Rate) Control Action
Control action in which the output is proportional to the

rate of change in the input (error)
d
m  Td e
dt
Temperature
Td = Minutes
85¡
80¡
75¡
+5
0
-5
Error Signal
Rate of
Change Over Time
74
© 2013, ISA
TS00E (v1.2)
37
The Effect of Adding Derivative
Derivative added
Gain increased
Integral action faster
75
Proportional + Integral + Derivative Control
76
© 2013, ISA
TS00E (v1.2)
38
Characteristics of Controller Modes
• Proportional
– Simple: easy to tune
– Experiences offset at steady state
• Proportional-plus-reset
– Most commonly used of all modern controller modes
– No offset
– Possibilities exist for instability due to lag introduced
• Proportional-plus-reset-plus-rate
– Rapid response
– No offset
– In slow loops, offers the least time away from setpoint with the least
overshoot (rate is not used in fast or noisy loops)
77
© 2013, ISA
TS00E (v1.2)
39
Week 8
Certified Control
Course – Week 8
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Pressure Gauges and Accessories
© 2013, ISA
TS00E (v1.2)
1
Start-Up Concerns
• Safety
• Documentation
• Process start up familiarity
Start-Up Safety Concerns
• Valve fail safe operation, if required

• Transmitter fail safe design
• Process hazards review (“What if” analysis)
• SIS review
• Shut down familiarity
• Safety and health concerns
• Material safety data sheets
• Electrical classification data
• Validate all shutdown components and their operating points
© 2013, ISA
TS00E (v1.2)
2
Start-Up Documentation
• Procedures for start-up, operations and shutdown

• P&IDs
• Loop diagrams
• Process hazards review
• Process reaction curve
• Maintenance and calibration procedures
• Loop components operation and accuracy specifications
Use the Proper Fittings

to make your life easier
for future Maintenance
© 2013, ISA
TS00E (v1.2)
3
Loop Checking Concepts
• Considerations
• Process
• Procedure
Loop Checking
Some think of loop checking as a process to confirm that the

components of the loop are wired correctly and is typically
something done prior to start-up. However, the loop check’s
scope has expanded to also include tests to confirm that it is
“operating as designed” and then to ongoing programs for
benchmarking and monitoring performance.
© 2013, ISA
TS00E (v1.2)
4
Loop Check Process
• Define/review procedure
– Purpose of loop check
– Determine and document the details of the procedure
– Make sure safe procedures are followed
• Review documentation
– Make sure appropriate documentation is available
– Make sure you have the latest version
– Make sure technicians are involved in the review of documents prior to
starting loop check
Loop Check Considerations
• Involves testing/checking individual loops

• Some organizations require the testing of each component of
the loop (and is a requirement for SIS - Safety Instrument
Systems)
• Usually occurs at that time when the majority of the construction
and installation has been completed and the system is being
prepared for startup
• In many cases will require the checking/testing of each
component in the loop individually, and then checking the
function of the loop as a whole
10
© 2013, ISA
TS00E (v1.2)
5
Loop Check Process (cont’d)
• Visually inspect loop components

– Location, mounting
– Conformity to documentation
• Check availability of utilities
– Air supply
– Electrical supply
– Verify that power sources can be individually isolated prior to any power
applications.
– Review local facility lock-out, tag-out, try-out procedures
• Check/test of individual component
– Operational check
– Calibration if necessary
11
Loop Check Procedure
• Perform functional loop test

• Adjust loop parameters for optimal process performance
calibrator (simulator)
12
© 2013, ISA
TS00E (v1.2)
6
Loop Checking
• Current day loop checking is arranged to follow a typical

automation project from design checkout at the factory
acceptance test (FAT) through to an ongoing sustaining loop
performance program. The steps of such projects are as
follows:
loop checking basics

the factory acceptance test (FAT)
start-up
performance benchmarking
sustaining the performance
13
Sensor/Transmitter
The loop starts here and cannot do a good job unless the measurement
is accurate and reproducible. Proper selection and installation of the
sensor and transmitter is critical based on service conditions, accuracy,
reproducibility, stability, reliability, and other plant standards.
Consider resolution
Deadtime and noise introduced by measurement installation location

can really hurt the loop performance.
the typical controller, proportional, integral and derivative

[PID] is challenged by dead band!
14
© 2013, ISA
TS00E (v1.2)
7
Controller
The controller compares the transmitter measurement (PV) to

the operator-entered set point (SP), calculates the difference
(error), acts on the error with a PID algorithm and outputs a
signal to the valve.
Insure the right tuning methods are applied!
15
Final Control Element

The final control element takes the signal from the controller and attempts to position the flow
controlling mechanism to this signal. There are various types of final control elements and
some have better performance in terms of “positioning” the device.
Final control elements can be variable speed drives for pumps or fans, dampers/louvers, the
most common is the control valve.
The valve receives an electrical signal from the controller, converts the electronic signal to a
pneumatic signal that must then drive an actuating device to a precise location.
The valve can introduce non-linearities and deadband into the loop. In receiving an electronic
signal and converting it to a valve plug/ball/disk position in the pipe, various sources of non-
linearity and deadband can build up.
Friction from seals and packing, backlash of mechanical parts, relay dead zones, shaft windup
can keep the valve from maintaining the signal required by the control system.
Proper valve sizing and selection of valve characteristic can help linearize the flow response to
controller output changes.
16
© 2013, ISA
TS00E (v1.2)
8
Other Controls
In addition to feedback control, technicians will encounter several other control

strategies when performing loop checking, such as cascade,
In some plants, the term “loop” may also include other control system functions
such as:
Analog Indicate Only
Motor Start/Stops
On-off Valves
Discrete Input/output type control functions.
You may include them in your plant’s loop check plan.
Vendor literature and application papers are good sources of information
17
Conclusion
This process starts when the instruments are received at the

plant site. It continues through installation and start-up and into
the ongoing plant operation.
This verification testing prior to start-up is known as the factory

acceptance test (FAT) which, as an option, can be duplicated at
site with the actual hardware and software installed, termed site
acceptance test (SAT).
18
© 2013, ISA
TS00E (v1.2)
9
Week 9
Certified Control
Course – Week 9
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Maintenance Management System Overview
A complete maintenance management system is available from

many different vendors and each promote there own product
benefits.
Maximo, Simplicity, Bigfoot, eMaint X3, Maintenance

Connection.
© 2013, ISA
TS00E (v1.2)
1
Maint Coordinator
Maint Scheduler
© 2013, ISA
TS00E (v1.2)
2
Task Planner
Task Calendar
© 2013, ISA
TS00E (v1.2)
3
Work & Request Order
SOP’s, Procedures
© 2013, ISA
TS00E (v1.2)
4
Parts Inventory
Contacts & Vendors
10
© 2013, ISA
TS00E (v1.2)
5
Personal Manager
11
Safety Inspections
12
© 2013, ISA
TS00E (v1.2)
6
Forms and Permits
13
Standard Operating Procedure
14
© 2013, ISA
TS00E (v1.2)
7
Week 10
Certified Control
Course – Week 10
TS00E Version 1.2
© 2013
Standards
Certification
Publishing
Exam Preparation Overview
Completed the CCST Review
What Next ?
© 2013, ISA
TS00E (v1.2)
1
30: How CCST Exam relates to TS00 Review Course
• TS00 uses the same knowledge and skills to develop

specific content areas.
• These topics are taught to the same level specified in the
knowledge and skills list.
• The CCST exam is not taught. CCST course topics are
approximately the same weighting as exam domain areas.
• ISA cannot use actual CCST questions in the course without
violating the integrity and validity of the exam.
• The CCST exam is an evaluation of your education and
experience, not a set of questions to be memorized, used,
and discarded.
To Become CCST Certified
Individuals must:
• Complete Application: Document education, training and/or

experience as a skilled technician:
The CCST Program offers three levels of certification based upon a

technician’s experience, education and training. Technicians can
begin testing directly at the level for which they can meet the
requirements.
• Remit the testing/application fee.

• Take and pass the certification examination.
© 2013, ISA
TS00E (v1.2)
2
Exam Development Background
• New exam questions are added to the item bank on an

ongoing basis by a convened group of qualified Subject Matter
Experts (SME)
• The exam writing sessions are led by a psychometrician (one
who specializes in test and measurement)
• Psychometrician also monitors statistical performance of all
exam questions on an ongoing basis – questions that do not
perform well statistically are pulled from the item bank.
• All exam questions must be referenced to a credible source
(technical publication) and this documentation stored for future
reference.
• All exam questions are reviewed by a pool of SMEs and rated
on difficulty level and categorized in the subject area before
being placed in the item bank.
Questions
• 175 total questions (Level I & III)

• Multiple choice, four choices
• No “all of the above” type
• All answers to a question have similar format
• Location of correct answer has been shuffled
• No trick questions
• Passing score developed by team of professionals and adjusted for problem
questions
• New questions developed continuously
• Time allotted for all exams is four hours.
© 2013, ISA
TS00E (v1.2)
3
Scoring
• The CCST exam is scored by a third party, as ISA is not

legally permitted to know the actual passing score, just the
pass or fail status of any particular individual.
• If you take the computer administered test (at a testing
center) you will be notified immediately as to whether you
passed the exam or not.
• You will either receive a statement stating you met the
examination requirements, or you did not, and the areas
where you had difficulty.
Prepare for the CCST Exam
Here are some of the many resources to help you prepare for
the CCST exam:
• Study Guides
Study Guide Level I
Study Guide Level II
Study Guide Level III
• Training Resources
Instructor-Led Courses
Online and CD Courses
• Publication Resources
Publication Resources
© 2013, ISA
TS00E (v1.2)
4
Steps in the Exam Process
• Apply online or download the application form by selecting
www.isa.org/CCST and choosing “Apply” from the left navigation
bar.
• Submit your completed application and fees to ISA by the
appropriate Testing Window application deadline date.
• If your application is deficient, you will be contacted by ISA and
given an opportunity to complete the application.
• When your application is approved, you will be mailed a testing
eligibility code.
• Go to www.prometric.com/ISA to locate a Prometric electronic
testing center near you, enter your testing eligibility code, and
schedule your exam date and location.
• You will receive an email from Prometric confirming your test date
and testing location.
• Report to the testing center at the scheduled time, carrying a valid,
government issued form of identification with a photo and signature,
and the exam confirmation letter you received from Prometric.
• You will receive your pass/fail results immediately after testing at the
Prometric test center.
• Those that passed the exam will appear on the CCST search pages
on the ISA program website.
9
Take the CCST Exam
• After submitting application, paying fee and being approved,

you will receive a confirmation letter with an access code to go
online to schedule your exam at a Prometric Testing Center
on a date/time that is convenient for you.
• All ISA CCST exams are closed book. No reference material

may be brought into the test site.
• You may use a non-programmable calculator. You will also

have access to the Microsoft on-line calculator during the
electronic exam and a common conversion formula referral
sheet.
10
© 2013, ISA
TS00E (v1.2)
5
Test Center Environment FAQ’s
• When should I plan to arrive at the testing center?

– You should arrive at the testing center at least 30 minutes before the test is
scheduled to begin.
• What type of identification must I bring to the test center?

– ID requirements vary for many exams; unfortunately we cannot list each on this
page. It is the examinee's responsibility to review the ID requirements for the
exam you are taking before making your appointment.
• In general, most exams require the following:

– For IT exams, you must have two valid forms of ID, one with a photo and both
with signature.
– For Academic or Professional Licensure & Certification exams, you must have
one valid government-issued ID bearing photo & signature. If the ID does not
have either the photo or signature, a secondary ID must be presented that does.
11
Test Center Environment FAQ’s (cont’d)
• What are acceptable forms of identification?

– Acceptable forms of photo identification include:
– Driver's license
– Passport
– Military identification
– Employee identification card
– Acceptable forms of non-photo identification include:
- Credit card
– Check cashing card
– Social Security cards are not considered acceptable forms of
identification
12
© 2013, ISA
TS00E (v1.2)
6
• Can my exam be taken on my PC, or do I have to go to

one of your centers to test?
– The exams we schedule must be administered at authorized testing sites.
• Are there lockers? Can I keep my purse with me?
– Because the only item allowed into the testing area is identification, we
encourage test takers to leave personal items at home. To accommodate
those items that cannot be left behind (such as purses), the testing
centers may have small lockers available.
13
• I am on medication. May I bring drinks/food into the

testing room?
– Food and drinks are not permitted in the testing rooms. Many of the
exams that we administer do allow you to take a break. The exams that
do not offer break time will allow you to leave the testing area to get a
drink or take medication. However, the amount of time designated for that
exam is not stopped when you are away from your computer.
• Do you provide special conditions equipment?
– Special equipment is available if requested and approved in advance by
your test sponsor. This request is then forwarded to the testing center to
implement the day of the exam. Please contact your test sponsor to
discuss your special testing needs.
14
© 2013, ISA
TS00E (v1.2)
7
How crowded are the testing rooms? I need to be in a

quiet environment.
– Many of the testing labs are set up with as many as 16 workstations,
although the number of candidates on a daily basis may vary. The aim is
to provide a quiet and comfortable environment for all test takers. Noise
reducing headsets are available for an even quieter environment. These
headsets are not to be confused with our audio headsets, which are used
for exams that contain audio sections, and are also available at each
testing station.
Can I choose my testing computer?

– Testing computers are predetermined. Our systems are set to provide the
next available computer to accommodate the length of the exam for which
you are scheduled.
15
Prometric Testing Center Regulations
• You will be continuously monitored by video, physical walk-

throughs and the observation window during your test. All
testing sessions are video and audio recorded.
• You are required to sign out on the test center roster each time you
leave the test room. You must also sign back in and show your ID to
the (TCA) in order to be re-admitted to the test room
16
© 2013, ISA
TS00E (v1.2)
8
Prometric Testing Center Regulations (cont’d)
• You are prohibited from communicating, publishing,

reproducing, or transmitting any part of your test, in any form
or by any means, verbal or written, for any purpose.
• You must not talk to other candidates or refer to their

screens, testing materials, or written notes in the test room.
• You must not use written notes, published materials, or other

testing aids, except those allowed by your test sponsor.
17
• You are allowed to bring soft ear plugs or center-supplied tissues in

the test room.
• You must not bring any personal/unauthorized items into the testing
room. Such items include but are not limited to: outerwear, hats,
food, drinks, purses, briefcases, notebooks, pagers, watches,
cellular telephones, recording devices, and photographic equipment.
• Any clothing or jewelry items allowed to be worn in the test room

must remain on your person at all times. Removed clothing or
jewelry items must be stored in your locker.
• Weapons are not allowed at any Prometric Testing Center.

You will be asked to empty and turn your pockets inside out prior
to every entry into the test room to confirm that you have no
prohibited items.
18
© 2013, ISA
TS00E (v1.2)
9
• You must return all materials issued to you at the center at

the end of your test.
• You must comply with the policy of your test sponsor

regarding the use of phones during scheduled breaks in
your test.
• You may have either scheduled or unscheduled breaks which

are determined by your test sponsor.
19
• Repeated or lengthy departures from the test room for

unscheduled breaks will be reported.
• If you need access to an item stored in the test center during a

break such as food or medicine, you must inform the center
administrator before you retrieve the item.
• You must conduct yourself in a civil manner at all times when

on the premises of the testing center. Exhibiting abusive
behavior towards the TCA, or any other staff member of the
test center, may result in criminal prosecution.
20
© 2013, ISA
TS00E (v1.2)
10
• To protect the privacy of all testers, the test center

administrator can neither confirm nor deny if any particular
individual is present or scheduled at the test center.
• Persons not scheduled to take a test are not permitted to wait

in the test center.
For more information:

• Visit the Prometric FAQ Page
• Visit the Prometric Testing Center Regulations
21
General CCST Exam Strategies
• For multiple choice, answer all the questions you know FIRST!
• Read the QUESTION, FORMULATE an answer, THEN read the
ANSWERS before moving forward …
– Eliminate answers you suspect are wrong
– Select from the remaining answers
• If a question seems too easy, it probably is
• Postpone multiple choice questions requiring extra time to analyze.
• For those you cannot recall or just don’t know, GUESS -- *
* However, the number of questions you need to guess

should be a small percentage of the test. If this is not so
then (unfortunately) you may be either unprepared or
unqualified for the testing level.
GOOD LUCK !! 22
© 2013, ISA
TS00E (v1.2)
11
ISA Membership
• ISA Membership is just $120 per year, which includes free

membership in two Technical Divisions (a $20 value) - one
from each Department: Automation and Technology and
Industries and Sciences.
– For more information, visit the web:

http://www.isa.org/membership/meminfo
– Email: info@isa.org or
– Contact ISA at (919) 549-8411
23
ISA Resources
• Books
• Software
• Videotapes/CD’s/DVDs
• Online courses
• Standards
• Journals
• Training courses
• Membership services
Phone: (919) 549-8411 E-mail Address: info@isa.org
24
© 2013, ISA
TS00E (v1.2)
12
Course Contributors
• Chuck Kirby
• Mark Weisner
• CCST job task analysis team
25
© 2013, ISA
TS00E (v1.2)
13
Pre-Course Exam Pre-Course Exam Pre-Course Exam Pre-Course Exam Pre-Course Exam
Pre-Course Exam
TS00E – Pre-Instructional Survey
Name: Date:
1. A pressure gauge that reads 100 PSIA is indicating PSIG.
a. 3.61
b. 85.30
c. 100.00
d. 114.70
2. The specific gravity of a gas is the ratio of the density of the gas to the density of when
compared under the same conditions.
a. air
b. water
c. gasoline
d. hydrogen
3. A temperature of 273.15 Kelvin is the same as _ºCelsius
a. 212.00
b. 186.64
c. 100.00
d. 0.00
4. A circuit has a 100 Ω resistor, a 50 Ω resistor, and a 200 Ω resistor all in parallel with each other.
What is the total resistance of the circuit?
a. 28.6 Ω
b. 35.0 Ω
c. 175 Ω
d. 0.28 M Ω
5. Primary standard reference units and physical constants are maintained by _.
a. NIST
b. testing labs
c. instrument tech’s
d. the plant instrument shop
6. You have a standard pneumatic instrument loop with a span of 200 units, what is the steady state
gain?
a. 0.06 PSIG/unit
b. 0.07 PSIG/unit
c. 0.08 PSIG/unit
d. 0.12 PSIG/unit
2013, ISA 1
TS00E (1.2)
7. control is often used when a specific blend of two different materials is required.
a. ratio
b. cascade
c. feedback
d. feed forward
8. There are approximately time constants from the point at which the process reaction
curve begins to change and reaching its maximum value.
a. 1
b. 3
c. 5
d. 7
9. An instrument location plan shows the _of each instrument
a. location, and wiring plan

b. location, elevation, and tag number
c. specification number, and tag number
d. location, specification number, and elevation
10. Maintenance that occurs following equipment failure is called _maintenance
a. creative
b. preventive
c. corrective
d. predictive
11. The single most important document in the drawing package defining and organizing a project is
the
a. specification sheets
b. layout drawings
c. P&IDs
d. PFDs
12. The PLC program can use logic to control the process
a. relay
b. ladder
c. analog
d. standard
13. A magnetic flow meter determines the flow of a process material by measuring the of the
fluid.
a. velocity
b. density
c. volume
d. temperature
2013, ISA 2
TS00E (1.2)
14. A only controller will have an offset from the desired set point.
a. integral
b. derivative
c. pneumatic
d. proportional
15. With a direct acting controller an increasing input will cause a (an) output.
a. continuous
b. decreasing
c. increasing
d. pulsating
16. When a d/p cell is used to measure hydrostatic pressure in an open tank and the transmitter is
mounted below the zero reference point for the level a error must be corrected for.
a. suppression
b. elevation
c. span
d. zero
17. A process where material is fed and removed from the process at the same time is called a
process.
a. batch
b. distillation
c. separation
d. continuous
18. The controlled variable may also be the variable.
a. distributed
b. disturbance
c. measured
d. handled
3
19. The density of water at standard temperature and pressure is lbs/ft .
a. 62.4
b. 27.7
c. 14.7
d. 0.433
20. The region between the limits within which a quantity is measured, received, or transmitted,
expressed by stating the lower and upper limits is called the _.
a. span
b. zero
c. range
d. linearity
2013, ISA 3
TS00E (1.2)
Homework Exercises Homework Exercises Homework Exercises Homework Exercises Homework Exercises
Homework Exercises
TS00E - PRACTICE EXAM 1
Name Date
This exam is to be taken home with you and completed prior to the next day's classes.
The exam will be reviewed during the first period the next day.
1. When a gas pressure is applied to the interior of an empty closed vessel the force is on
all surfaces.
A. undiminished
B. halved
C. doubled
D. independent
2. A controller is being tuned for a fast control loop. It has proportional action and the gain has been
adjusted for a value by the technician. As reset action is added to the loop, which of the following
will need to take place? The technician will need to _.
A. Add derivative
B. Increase the gain
C. Decrease the gain
D. Increase the dead time
3. What is the current flow in a circuit with a 24 VDC power supply and a resistance load of 2000
ohms?
A. 12 amps
B. .020 amps
C. 20 mA
D. 12 mA
4. Each controller has instructions as part of the device which affects the controller output based on
the error signal. These are pre set based on the dynamic loop response and are referred to by
which of the following terms:
A. algorithm
B. reverse band
C. process lead lag
D. error compensation
5. In an automobile instrumentation system, the fuel level and the coolant temperature are displayed
to the driver and are examples of :
A. setpoint
B. distributed variable
C. measured variable
D. disturbance variable
2013, ISA 4
TS00E (1.2)
6. Which of the following calibration instruments will be the best choice to calibrate a high range
electronic pressure transmitter for a range of 0 to 1000 PSIG?
A. decade box
B. squeeze bulb
C. function generator
D. dead weight tester
7. Approximately what is the pressure, in psig, on the bottom of a 10 ft, flat bottom, open tank filled to
100% of capacity with a fluid that has a specific gravity of 1.1?
A. 2.50
B. 4.75
C. 9.50
D. 25.4
8. A process variable, which is to be maintained at some desired value (temperature, pressure, level,
flow) by means of manipulating another process variable, is the:
A. measure variable
B. controlled variable
C. disturbance variable
D. manipulated variable
9. A fluid is flowing through a 10-inch diameter pipe at a velocity of 6 ft/sec. W hen the pipe reduces
to an 8-inch diameter, and all other flowing parameters remain the same, the fluid velocity
becomes ft/sec.
A. 2.550
B. 6.075
C. 9.375
D. 12.75
10. Liters per minute is a unit of measurement for:
A. flow
B. level
C. pressure
D. temperature
11.Which of the following is not required for feed forward control applications?
A. Three mode controller

B. Timing for the correction
C. Measurement of the disturbance
D. What to correct for the disturbance
12. When working with an instrument air system, the of the air is a critical measurement and
is dealt with in the ANSI/ISA 7.0 standard.
A. pressure
B. dew point
C. source humidity
D. molecular weight
2013, ISA 5
TS00E (1.2)
13. The range of values over which an input signal may be changed upon reversal of direction
without any observable or measurable change in output is called:
A. instrument accuracy
B. reverse precision
C. dead band
D. zero point
14. A typical process control loop must contain at least components:
A. 2
B. 3
C. 5
D. 6
15. A 12-volt battery rated to produce 2 amps of current for 30 hours is connected to a 400 ohm load.
How long should the battery remain an energy producing capability?
A. 2 hours
B. 100 hours
C. 1500 hours
D. 2000 hours
16. A three wire RTD transmitter output is more accurate than a two wire arrangement. This increase
in accuracy is due to which of the following:
A. Lead temperature will not affect the output

B. Lead resistance affects are minimized
C. A simple transmitter may be used
D. Junction resistance is eliminated
17. If the measurement is calibrated for +50 to +250 degrees F, what milliamp output would represent
+175 degrees F?
A. 8.0 milliamps
B. 12.0 milliamps
C. 14.0 milliamps
D. 16.0 milliamps
18. A plant has a 40 ft. high water tank mounted on top of a 50 ft. platform. What is the water level in
the tank, measured in feet, if a pressure gage on a lower level, height 15 ft, reads 30 psig?
A. 12.3
B. 27.3
C. 34.3
D. 39.3
19. A properly calibrated pressure transmitter connected to a 15 ft. tall open tank with a water level of
7.5 ft. would indicate a pressure of approximately
A. 9 psig.
B. 15 psig.
C. 90 inches of water.
D. 120 inches of water.
2013, ISA 6
TS00E (1.2)
20. The internal components of a control valve are generally referred to as the ?
A. yoke
B. valve trim
C. both A and B
D. none of the above
2013, ISA 7
TS00E (1.2)
Name Date
1. What is the value of a resistor that is color coded: green - brown - orange - gold?
A. 51K ohms + or -5%

B. 80K ohms + or - 5%
C. 51 ohms + or - 10%
D. 503 ohms + or - 10%
2. From the list given below, select the group that is the United States representative to the International
Electrotechnical Commission (IEC)
A. ISA B.
ANSI C.
ASTM D.
AIChE
3. The ratio of the maximum flow that a flow meter can measure within the stated accuracy to the
minimum flow that can be measured within the stated accuracy is called the
.
A. Span
B. Range
C. Dead Band
D. Turndown Ratio
4. The Reynolds Number for a flowing fluid is most affected by which of the following parameters:
A. Viscosity
B. Pressure
C. Friction factor
D. Temperature
5. A transmitter is calibrated for +40 to +140 inches of water for a level application. This is a
zero range.
A. Suppressed
B. Elevated
C. Nominal
D. Biased
6. A Resistance Temperature Detector (RTD) for industrial use, typically is made of

wire and has a 0ºC nominal ohmic resistance of ohms:
A. copper, 20
B. tungsten, 75
C. platinum, 100
D. iridium-oxide, 180
2013, ISA 8
TS00E (1.2)
7. As outlined in ISA 5.1 -1984 (R1992) Instrumentation Symbols and Identification, when using an
electronic loop diagram to locate a field junction box you would look for a
A. circle
B. ellipse
C. square
D. diamond
8. A differential pressure transmitter connected across an orifice plate in gas service by flange taps
and sensing (impulse) lines will probably experience abnormal readings if:
A. sense lines are of equal height and length

B. meter is mounted below process line
C. meter is mounted above process line
D. sense lines are condensate free
9. As used in instrumentation and defined in the ISA Dictionary, the term, "primary element" usually
refers to:
A. outer cascade loop

B. pneumatic control valves
C. transmitters / transducers
D. process detectors or sensors
10. To change a 4 to 20 mA analog signal from a transmitter to the signal required by a digital
controller, a(n) must be between the transmitter and controller in the measurement loop.
A. I/P transducer
B. P/I transducer
C. DP transmitter
D. A/D Converter
11. If it is desired to measure the mass flow rate of a liquid, a mass flow meter employing
measurement based on the principle would be the applicable choice
A. Coriolis
B. Faraday
C. King
D. Bernoulli
12. When performing level measurement, which of the following level measurement applications is
referred to as “non contact”
A. Ultrasonic
B. Dip stick
C. Absolute pressure
D. head pressure
13. When performing flow measurement on pipe sizes greater than 8 inches in diameter and it is
desired to achieve the largest differential pressure drop for a particular flow, you would normally
locate the pressure taps?
A. in the orifice flanges

B. at the vena contracta points
C. at the permanent recovery points
D. at random points up and down stream
2013, ISA 9
TS00E (1.2)
14. A field mounted device that changes the signal from a differential pressure measurement sensor
into a standard signal that can be used by a receiving instrument located in a control room is
usually called a:
A. DP transducer
B. DP transmitter
C. Signal converter
D. Signal Conditioner
15. Using a Type “J” thermocouple ranged from -105 ºC to +250ºC if the reference junction
temperature is at 0 ºC, what happens to the voltage at the thermocouple terminals when the
temperature drops from +25 ºC to -25 ºC?
A. The polarity will reverse and voltage will become more positive.
B. The polarity will reverse and voltage will become more negative.
C. The polarity will remain the same and voltage will become more positive.
D. The polarity will remain the same and voltage will become more negative.
16. In order to prevent condensation in the instrument air supply it is critical that the dew point be
measured. Normally in an instrument air supply system the dew point is usually measured:
A. After the air leaves the dryer

B. Before the air enters the dryer
C. After the air leaves the separator
D. Before the air enters the compressor
17. A control valve that utilizes a stem sliding through a packing gland, positioning a plug and pushes
against a seat ring to close the valve is often referred to as a:
A. Rotary motion control valve

B. Linear motion control valve
C. Ball control valve
D. Diaphragm control valve
18. Using ISA 5.1-1984 (R1992) Instrumentation Symbols and Identification; the loop in which an
instrument is located is identified by:
A. one, two, three, or four letters in the upper half of the symbol
B. a numeric that is the same for all instruments in a specific loop
C. identifies the measured or initiating variable and clarifying suffixes
D. appears in the upper portion of the instrument symbol with a numeric
19. A protective tube which is identified as having an insertion length, an immersion length, and has a
particular material of construction is also known as a(n):
A. thermowell
B. type of manometer
C. expandable bellows
D. instrument reservoir
2013, ISA 10
TS00E (1.2)
20. When bundling and running cables in conduit and duct, the listed conductors are normally
separated in different duct or conduit runs based on signal type. W hich type would normally be
shielded?
A. power wires
B. signal wires
C. ground wires
D. control wires
2013, ISA 11
TS00E (1.2)
Name Date
1. As outlined in ISA 5.1 -1984 (R1992) Instrumentation Symbols and Identification, when using a
P&ID diagram, a discrete controller will be
identified as a
A. rectangle
B. triangle
C. square
D. circle
2. Using a pneumatic temperature transmitter with a 3-15 psig output and ranged from +150 to +450
degrees F. If the applied temperature is +298 degrees F, what is the transmitter output?
A. 5.7
B. 7.2
C. 8.9
D. 12.6
3. When measuring flow Faraday’s law is used in which instrument to infer velocity of the flowing
liquid?
A. mass flowmeter
B. nutating disk meter
C. magnetic flowmeter
D. positive displacement meter
4. A positioner can be used to:
A. modify the action of the valve, extend the stroke, increase the pressure on the valve actuator,
or send an end of travel signal.
B. modify the action of the valve, extend to stroke, increase the pressure on the valve actuator
and or modify the control valve flow characteristics
C. modify the action of the valve, extend the stroke, increase the pressure on the valve actuator,
or change the input signal from the pressure to current
D. modify the action of the valve, extend the stroke, increase the pressure on the valve actuator,
or change the valve coefficient.
5. An instrument loop device used to change an electrical signal to a pneumatic signal is most often
called a:
A. signal conditioner
B. transducer
C. transmitter
D. converter
2013, ISA 12
TS00E (1.2)
6. One of the main reasons for using a piston actuator for a control valve in an instrument loop will
be where:
A. the application normally does not need a pneumatic positioner

B. it can be only actuated by hydraulic pressure above 100 psig
C. it could be made fail safe with simple electric limit switches
D. a long stroke or high actuator pressure is required
7. While maintaining a 1 psi drop across a control valve, at 25% open it passes 25% of full capacity,
when it is 50% open, 50% of its capacity when 75% open, 75% of its capacity; the inherent
characteristic is:
A. equal percentage
B. quick opening
C. throttling
D. linear
8. One of the methods of measuring level by inference uses differential pressure transmitters to
measure level by:
A. capacitance
B. conductivity
C. thermal energy
D. hydrostatic head
9. A flowmeter constructed with a rotor mounted axially within a pipe mounted on a set of sealed
bearings, generally including some form of straightening vanes, and using a reluctor or “Hall
Effect” pickup describes which type of flowmeter?
A. water meter
B. venturi tube
C. magnetic
D. turbine
10. There is a two-stage phenomenon in liquid flow. The first stage is the formation of voids and
cavities within the liquid system when the line pressure falls below the vapor pressure. The
second stage is the collapse or implosion of these cavities back into an all-liquid state when the
line pressure recovers above the vapor pressure and this stage is called:
A. cavitation
B. abrasion
C. erosion
D. flashing
11. In a process where the composition of the flow is such that elastomers are permissible, then
to reduce the abrasive effects of a slurry flow; valves would be a good choice.
A. eccentric spherical plug

B. double V port globe
C. single port globe
D. diaphragm
2013, ISA 13
TS00E (1.2)
12. In a typical petrochemical control system, a significant advantage of an electromechanical
actuator over a hydraulic or pneumatic actuator is:
A. a low cost when compared to pneumatic actuators

B. they can be easily made "fail safe (open or closed)"
C. their typical very low maintenance requirements
D. no requirement for a clean dry instrument air
13. Of the following types of actuators, which type offers higher thrust capabilities in a smaller
actuator size due to being able to use higher air pressures?
A. piston
B. motor driven
C. rolling diaphragm
D. spring and diaphragm
14. In a bubbler (dip tube) level measuring system, for a bubble to be emitted at the open end of the
purge pipe the air pressure at that point is the pressure exerted by the liquid at that point.
A. twice
B. equal to
C. less than
D. three times
15. From ISA standard ISA5.1, "Instrument symbols and Identification," this primary element symbol
identifies a(an):
A. flow nozzle
B. orifice plate
C. venturi tube
D. vortex sensor
16. When using the parity system to detect transmission errors, the parity bit is set to a one or a zero
based on the content of the:
A. bits in the data word

B. start bit and bits in the data word
C. bits in the data word, including parity
D. bits in the data word, parity and the stop bit
17. When using a dip pipe (bubbler) system for tank level measurement, and the tank is 20 feet in
height above the minimum level, the dip pipe will be connected to the:
A. instrument air supply

B. low side of the dP cell
C. high side of the dP cell
D. dP cell output signal line
2013, ISA 14
TS00E (1.2)
18. After replacement of a new plug and seat in a control system valve, there is a process of grinding
the plug and seat together with an abrasive solution in order to have them seat correctly and seal
off the process fluid. This operation is called:
A. characterizing
B. linearizing
C. calibrating
D. lapping
19. The Reynolds number determines:
A. the venturi effect coefficient

B. the fluid viscosity in centistokes
C. the coriolis acceleration in lbs/hour
D. whether the fluid flow is laminar or turbulent
20. Installing a concentric orifice plate used in liquid service with the weep hole in the lower section of
the orifice plate will result in:
A. damage to the plate

B. entrained gas problems
C. very low meter readings
D. very high meter readings
21. A cylindrical displacer of 36 inch length and 6 inch in diameter is located at the interface (air and
water) in a 72” tank. Immersed to 24 inches in a fluid with a specific gravity of 1.00 it is displacing
24.5 lbs of water as determined by the torsion bar scale. W hat is the probable cause of error, if
any?
A. displacer wrong for specific gravity

B. displacer has absorbed fluid
C. displacer linkage is binding
D. there is no error
2013, ISA 15
TS00E (1.2)
Course Presentation
Answer Sheets Course
Answer
Presentation
Sheets Course
Answer
Presentation
Sheets Answer
Course Presentation
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Course
Sheets
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Answer Sheets
Course
Additional
Presentation
Resources Additional
Course Resources
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Course Presentation
Resources Additional
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CourseResources
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Additional Resources
Additional Resources from ISA
Related ISA Books

• Automation Network Selection by Dick Caro
• Cascading Logic: A Machine Control Methodology for Programmable Logic
Controllers by Gary Kirckof, P.E.
• Control Valve Primer, 3rd Edition by H.D. Baumann
• Control Valves by Guy Borden, Jr. and Paul G. Friedmann
• Design and Application of Process Control Systems by A. B. Corripio
• Electrical Instruments in Hazardous Locations, 4th Edition by E.C. Magison
• Good Tuning: A Pocket Guide by G.K. McMillan
• Industrial Data Communications, 3rd Edition by L.M. Thompson
• Programmable Controllers, 4th Edition by T.A. Hughes
• Safety Instrumented Systems: Design, Analysis, and Justification 2nd Edition, by
Paul Gruhn and Harry L. Cheddie
• Successful Instrumentation and Control Systems Design (with CD) by Michael D.
Whitt
• Troubleshooting: A Technician's Guide by William L. Mostia
• Tuning of Industrial Control Systems 2nd Edition by A. B. Corripio
Related ISA Standards

• ISA5.1-1984 (R1992), Instrumentation Symbols and Identification
• ISA51.1-1979 (R 1993), Process Instrumentation Terminology
2013, ISA 1
TS00E (1.2)
UNITS CONVERSION TABLES
Table 1 Multiples and Submultiples of SI Units

Table 2 Length Units
Table 3 Area Units
Table 4 Volume Units
Table 5 Mass Units
Table 6 Density Units
Table 7 Volumetric Liquid Flow Units
Table 8 Volumetric Gas Flow Units
Table 9 Mass Flow Units
Table 10 High Pressure Units
Table 11 Low Pressure Units
Table 12 Speed Units
Table 13 Torque Units
Table 14 Dynamic Viscosity Units
Table 15 Kinematic Viscosity Units
Table 16 Temperature Conversion Formulas
2013, ISA 2
TS00E (1.2)
Table 1: Multiples and Submultiples of SI units
Prefix Symbol Multiplying Factor
18
exa E 10 1 000 000 000 000 000 000
15
peta P 10 1 000 000 000 000 000
12
tera T 10 1 000 000 000 000
9
giga G 10 1 000 000 000
6
mega M 10 1 000 000
3
kilo k 10 1 000
2
hecto* h 10 100
deca* da 10 10
-1
deci* d 10 0.1
-2
centi c 10 0.01
-3
milli m 10 0.001
-6
micro u 10 0.000 001
-9
nano n 10 0.000 000 001
-12
pico p 10 0.000 000 000 001
-15
femto f 10 0.000 000 000 000 001
-18
atto a 10 0.000 000 000 000 000 001
* these prefixes are not normally used
Table 2: Length Units

Millimeters Centimeters Meters Kilometers Inches Feet Yards Miles
mm cm m km in ft yd mi
1 0.1 0.001 0.000001 0.03937 0.003281 0.001094 6.21e-07
10 1 0.01 0.00001 0.393701 0.032808 0.010936 0.000006
1000 100 1 0.001 39.37008 3.28084 1.093613 0.000621
1000000 100000 1000 1 39370.08 3280.84 1093.613 0.621371
25.4 2.54 0.0254 0.000025 1 0.083333 0.027778 0.000016
304.8 30.48 0.3048 0.000305 12 1 0.333333 0.000189
914.4 91.44 0.9144 0.000914 36 3 1 0.000568
1609344 160934.4 1609.344 1.609344 63360 5280 1760 1
Table 3: Area Units

Millimeter Centimeter Meter Inch Foot Yard
square square square square square square
2 2 2 2 2 2
mm cm m in ft yd
1 0.01 0.000001 0.00155 0.000011 0.000001
100 1 0.0001 0.155 0.001076 0.00012
1000000 10000 1 1550.003 10.76391 1.19599
645.16 6.4516 0.000645 1 0.006944 0.000772
92903 929.0304 0.092903 144 1 0.111111
836127 8361.274 0.836127 1296 9 1
2013, ISA 3
TS00E (1.2)
Table 4: Volume Units
Centimeter Meter Inch Foot US Imperial
Liter US barrel (oil)
cube cube cube cube gallons gallons
3 3 3 3
cm m ltr in ft US gal Imp. gal US brl
1 0.000001 0.001 0.061024 0.000035 0.000264 0.00022 0.000006
1000000 1 1000 61024 35 264 220 6.29
1000 0.001 1 61 0.035 0.264201 0.22 0.00629
16.4 0.000016 0.016387 1 0.000579 0.004329 0.003605 0.000103
28317 0.028317 28.31685 1728 1 7.481333 6.229712 0.178127
3785 0.003785 3.79 231 0.13 1 0.832701 0.02381
4545 0.004545 4.55 277 0.16 1.20 1 0.028593
158970 0.15897 159 9701 6 42 35 1
Table 5: Mass Units
Grams Kilograms Metric tonnes Short ton Long ton Pounds Ounces
g kg tonne shton Lton lb oz
1 0.001 0.000001 0.000001 9.84e-07 0.002205 0.035273
1000 1 0.001 0.001102 0.000984 2.204586 35.27337
1000000 1000 1 1.102293 0.984252 2204.586 35273.37
907200 907.2 0.9072 1 0.892913 2000 32000
1016000 1016 1.016 1.119929 1 2239.859 35837.74
453.6 0.4536 0.000454 0.0005 0.000446 1 16
28 0.02835 0.000028 0.000031 0.000028 0.0625 1
Table 6: Density Units

Gram/milliliter Kilogram/meter cube Pound/foot cube Pound/inch cube
3 3 3
g/ml kg/m lb/ft lb/in
1 1000 62.42197 0.036127
0.001 1 0.062422 0.000036
0.01602 16.02 1 0.000579
27.68 27680 1727.84 1
Table 7: Volumetric Liquid Flow Units

Meter Foot Foot US US barrels
Liter/second Liter/minute
cube/hour cube/minute cube/hour gallons/minute (oil)/day
3 3 3
L/sec L/min M /hr ft /min ft /hr gal/min US brl/d
1 60 3.6 2.119093 127.1197 15.85037 543.4783
0.016666 1 0.06 0.035317 2.118577 0.264162 9.057609
0.277778 16.6667 1 0.588637 35.31102 4.40288 150.9661
0.4719 28.31513 1.69884 1 60 7.479791 256.4674
0.007867 0.472015 0.02832 0.01667 1 0.124689 4.275326
0.06309 3.785551 0.227124 0.133694 8.019983 1 34.28804
0.00184 0.110404 0.006624 0.003899 0.2339 0.029165 1
2013, ISA 4
TS00E (1.2)
Table 8: Volumetric Gas Flow Units
Normal meter cube/hour Standard cubic feet/hour Standard cubic feet/minute
3
Nm /hr scfh scfm
1 35.31073 0.588582
0.02832 1 0.016669
1.699 59.99294 1
Table 9: Mass Flow Units

Kilogram/hour Pound/hour Kilogram/second Ton/hour
kg/h lb/hour kg/s t/h
1 2.204586 0.000278 0.001
0.4536 1 0.000126 0.000454
3600 7936.508 1 3.6
1000 2204.586 0.277778 1
Table 10: High Pressure Units

Kilogram
Pound/square force/ Millimeter
Bar Kilopascal Megapascal Atmospheres
inch centimeter of mercury
square
2
bar psi kPa MPa kgf/cm mm Hg atm
1 14.50326 100 0.1 1.01968 750.0188 0.987167
0.06895 1 6.895 0.006895 0.070307 51.71379 0.068065
0.01 0.1450 1 0.001 0.01020 7.5002 0.00987
10 145.03 1000 1 10.197 7500.2 9.8717
0.9807 14.22335 98.07 0.09807 1 735.5434 0.968115
0.001333 0.019337 0.13333 0.000133 0.00136 1 0.001316
1.013 14.69181 101.3 0.1013 1.032936 759.769 1
Table 11: Low Pressure Units

Meter of Foot of Centimeter of Inches of Inches of
Pascal
water water mercury mercury water
mH2O ftH2O cmHg inHg inH2O Pa
1 3.280696 7.356339 2.896043 39.36572 9806
0.304813 1 2.242311 0.882753 11.9992 2989
0.135937 0.445969 1 0.39368 5.351265 1333
0.345299 1.13282 2.540135 1 13.59293 3386
0.025403 0.083339 0.186872 0.073568 1 249.1
0.000102 0.000335 0.00075 0.000295 0.004014 1
2013, ISA 5
TS00E (1.2)
Table 12: Speed Units
Meter/second Meter/minute Kilometer/hour Foot/second Foot/minute Miles/hour
m/s m/min km/h ft/s ft/min mi/h
1 59.988 3.599712 3.28084 196.8504 2.237136
0.01667 1 0.060007 0.054692 3.281496 0.037293
0.2778 16.66467 1 0.911417 54.68504 0.621477
0.3048 18.28434 1.097192 1 60 0.681879
0.00508 0.304739 0.018287 0.016667 1 0.011365
0.447 26.81464 1.609071 1.466535 87.99213 1
Table 13: Torque Units

Newton meter Kilogram force meter Foot pound Inch pound
Nm kgfm ftlb inlb
1 0.101972 0.737561 8.850732
9.80665 1 7.233003 86.79603
1.35582 0.138255 1 12
0.112985 0.011521 0.083333 1
Table 14: Dynamic Viscosity Units

Centipoise* Poise Pound/foot·second
cp poise lb/(ft·s)
1 0.01 0.000672
100 1 0.067197
1488.16 14.8816 1
Table 15: Kinematic Viscosity Units

meter
Centistoke* Stoke Foot square/second
square/second
2 2
cs St ft /s m /s
1 0.01 0.000011 0.000001
100 1 0.001076 0.0001
92903 929.03 1 0.092903
1000000 10000 10.76392 1
*note: centistokes x specific gravity = centipoise
Table 16: Temperature Conversion Formulas

Degree Celsius (°C) (°F - 32) x 5/9
(K - 273.15)
Degree Fahrenheit (°F) (°C x 9/5) + 32
(1.8 x K) - 459.67
Kelvin (K) (°C + 273.15)
(°F + 459.67) ÷ 1.8
2013, ISA 6
TS00E (1.2)
TS00E - Additional Resource
ISA Resources for CCST® Preparation
ISA Resources Certification Domain
1 2 3 4 5 6 7
BOOKS
CCST Study Guide Level I X X X X
CCST Study Guide Level II X X X X X X
CCST Study Guide Level III X X X X X X X
Condensed Handbook of Measurement & Control X X
Control System Documentation: Applying Symbols X
and Identification
Control System Safety Evaluation and Reliability X X
Electrical Instruments in Hazardous Locations X X
Electrical Measurements and Calibration X
Fundamentals of Process Control Theory X
ISA Handbook of Measurement Equations and X
Tables
Maintainability and Maintenance Management X
Maintenance of Instruments & Systems X X X X X
Measurement and Control Basics X X
Preventive Maintenance X
Process Control: A Primer for the Non-specialist and X X
the Newcomer
Programmable Controllers X
Safety Shutdown Systems: Design, Analysis and X X
Justification
Service Parts Handbook X
Start-Up: A Technician's Guide X
Statistical Process Control X
Troubleshooting: A Technician's Guide X
Tuning of Industrial Control Systems X
Understanding Distributed Processor Control X
Systems for Control
DVDs
Instrumentation Basic Series (15 topics)
Feedback Control X
Primary Calibration Standards X
Pneumatic Test Equipment X
Electronic Test Equipment X
Oscilloscopes X
2011, ISA 7
TS00E (1.0)
1 2 3 4 5 6 7
Instrumentation Errors X
Instrument Calibration X
Process Control Modes X
Process Characteristics X X
Process Variables X
Instrumentation Symbols X
Instrument Loop Diagrams X
Process and Instrumentation Diagrams X
Mechanical Connections X
Electrical Connections X
Electronic Maintenance Series (12 topics)
Solid State Devices X
Integrated Circuits and Op Amps X
Sensor and Transducer Principles X
Transmitters X X X X
Transducers X X X X
Controllers, Indicators, and Recorders X X X X
Tuning X X
Sampling Systems and Gas Chromatograph Valves X X
Gas Chromatograph Ovens and Controllers X X
Spectroscopic Analyzers X X X
Electrochemical Analyzers X X X
Instrument Loop Troubleshooting X
Automatic Process Control Series (3 topics)
Basic Automatic Process Control X
Advanced Process Control X
Digital Control Techniques
Instrument Calibration Series (3 topics)
Principles of Calibration X
Calibrating Pressure and Temperature Instruments X
Calibrating Flow and Level Instruments X
Industrial Measurement Series (4 topics)
Flow X
Level X
Pressure X
Temperature X
Control Valve & Actuator Series (2 topics)
Introduction to Control Valves X
Selection and Sizing of Valves and Actuators X
2011, ISA 8
TS00E (1.0)
1 2 3 4 5 6 7
Training Courses
FG07: Introduction to Industrial Automation and X X X X
Control
FG15: Developing and Applying Standard X X X X
Instrumentation and Control Documentation
TC05: Tuning Control Loops X X
TC10: Troubleshooting Instrumentation and Control X X X
Systems
TI15: Electrical Systems and Principles X X X
TI20: Industrial Electronics X X X
TI21: Electrical Noise Effects on Instrumentation X X X
Control Equipment
TC30P: PLC/PAC Automation: Basic Structure, X X X X
Programming, Installation and Maintenance
TC36P: PLC/PAC Automation: Advanced Systems X X X X
Integration, Programming and Design
SP15: Applying Motor Control Drives X X X X
TI06: Maintaining Pneumatic Components in X X X X X
Measurement and Control
TI25: Installing, Calibrating, and Maintaining X X X X X X X
Electronic Instruments
TS16: Advanced Operation of Digital (Smart) X X X X X X
Transmitters
TS00: Certified Control System Technician (CCST) X X X X
Level I Review Course
TS06: Industrial Data Communications Systems X
TS12: Industrial Networking and Security X
EI30: Sizing, Selecting, and Applying Process X X X X
Control Valves
EI05: Industrial Pressure and Level Measurement X X X X
Engineering
EI10: Industrial Flow Measurement Engineering X X X X
ES10: Applying Instrumentation in Hazardous X X X X
(Classified) Locations
EC50: Safety Instrumented Systems - Design, X X X X X X
Analysis, and Justification
EC52: Advanced Safety Integrity Level (SIL) X X X X X X
Selection
EC54: Advanced Design and SIL Verification X X X X X X
2011, ISA 9
TS00E (1.0)

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Certified Control System

Technician® (CCST®) Level I

All rights reserved. This book or any portion thereof

The unauthorized reproduction or distribution of a copyrighted work is illegal. Criminal copyright

Week/Module 1: Overview of CCST Certification

Week/Module 2: Domain 1 -- Calibration, Maintenance, Repair and Troubleshooting

Week/Module 3: Domain 1 -- Calibration, Maintenance, Repair and Troubleshooting

Week/Module 5: Domain 2 -- Project Start-up, Commissioning, Loop-checking, Project

Week/Module 6: Domain 2 -- Project Start-up, Commissioning, Loop-checking, Project

Week/Module 7: Domain 2 -- Project Start-up, Commissioning, Loop-checking, Project

Week/Module 8: Domain 3 -- Project Start-up

Week/Module 9: Domain 3 -- Instrument Maintenance

Week/Module 10: Domain 3 -- Documentation

• Live Instructor Q&A Review

Learn more with ISA’s hands-on

General Course Goals

Developing a Certification Exam

• On February 16, 1995, ISA Executive Board approved the

Domain Level 1 Level 2 Level 3

1: Calibration, Maintenance, 77% 61% 19%

2: Project Start-up 16% 23% 13%

3: Documentation 7% 10% 10%

4: Admin, Supervision, N/A 6% 59%

Task for Level 1 Technician

0106 Obtain applicable documents required to perform device calibration, testing,

Task for Level 1 (continued)

0112 Isolate a process component from an operational system by following maintenance

0301 Document calibration, maintenance, troubleshooting, and repair using appropriate

Control Systems Technician (CST) Defined

• Skilled in and knowledgeable of pneumatic, mechanical, and electronic

– Typically, has received training in such specialized subjects as:

– Acquainted with both pipe fitting and electrical fundamentals

CCST® Program Definition

• The program promotes the professional development of the

• The program ensures high level of skill and competency, and is

• This is a “high stakes program”. Some companies hire,

• Document education, training and/or experience as a

• Understand process control loops and systems, including both

• Must pass the appropriate examination

2: Deming-father of manufacturing quality

Born: October 14, 1900

Died December 20, 1993

Alma Univ of Wyoming, Univ of

The main elements of an ISO standard quality system are:

– Quality Management System

ISO 9000 Standards

• Developed by the International Organization for

• Represent the common denominator of business quality

• In 1988, the Commission of European Communities (EC)

ISO 9001: 2008

• Has become the requirement for business in Europe

ISO Effect on I and C Departments

• "The emerging employment problem in manufacturing is not a

• We, “Instrumentation Professionals” are not exempt from

• The future looks very bright for technicians and engineers.

3: Concepts of Process Control

The Industrial Revolution

• 1920’s Manual Process Control

• A process is a part of a manufacturing plant in which material or

Continuous / Batch Process

• Continuous-Material is fed and removed at the same time, individual

• Batch- Material is added or blended, a process takes place and then

Batch Process Example