ESAA Intermediate Level Exam case studies
ESAA Intermediate Level Exam · Put your knowledge to work in context.
The ESAA Intermediate Level Exam is a multiple-choice credential aimed at working electrical and automation technicians who already have foundational field experience and want independent verification of their knowledge. It suits maintenance electricians, controls technicians, and reliability staff who troubleshoot power systems, motors and drives, instrumentation loops, and PLC-controlled processes. The ESAA Intermediate Level Exam case studies are 5 cases and about 4,214 words.
1High-Inertia Conveyor Trips on Overcurrent and DC Bus Overvoltage
A 75 hp, 460 V, 4-pole conveyor motor (FLA 96 A) is driven by a 110 A rated VFD through 350 ft of shielded VFD cable. The conveyor has a high-inertia load and a 12 s acceleration ramp.
828 words, about 4 min2Feedwater Flow Reading Disagrees with a Portable Ultrasonic Meter
A 6 in schedule 40 boiler feedwater line carries 230 °F water at 400 psig. Flow is measured by a concentric orifice plate with flange taps and a DP transmitter ranged 0 to 200 inH2O, producing 4–20 mA.
860 words, about 4 min3Intermittent Remote I/O Rack Fault on a Packaging Line
A packaging line uses a PLC with a local rack and two remote I/O racks connected by EtherNet/IP. Remote rack 2 faults intermittently every 4 to 8 hours; the fault clears after a power cycle or sometimes by itself.
838 words, about 4 min4Arc Flash Label and PPE After a Transformer Upgrade
A 480 V, 1200 A MCC is fed from a 2000 kVA utility transformer with 5.75% impedance. The available bolted fault current at the MCC line side is calculated at 41.8 kA, plus motor contribution.
872 words, about 4 min5Repeat Motor Bearing Failures on a Cooling Water Pump
A 100 hp, 460 V, 1780 rpm cooling water pump runs continuously. The motor has grease-lubricated bearings and is directly coupled to a centrifugal pump.
816 words, about 4 min