ESAA Intermediate Level Exam study plan

Calculate apparent, active and reactive power for balanced three-phase loads and convert between them using the power triangle

Derive per-unit values for a simple radial system and explain why per-unit simplifies transformer and fault calculations

Sketch the single-line diagram of a typical industrial distribution system from utility service through MCC and label each voltage level

Compute voltage drop on a feeder given conductor impedance, current and power factor, and state whether it meets a 3 percent limit

Explain how transformer impedance and source strength set available fault current, and estimate fault current for a 1500 kVA transformer at 480 V

Identify the purpose of grounding, bonding and the equipment grounding conductor in a low-voltage industrial system

Locate and interpret the overcurrent protection, conductor sizing and ampacity tables used for feeder design

Distinguish between arc flash, arc blast and shock hazards and state the boundary concept behind each

Describe the construction and torque-speed characteristic of an induction motor and identify slip at rated load from nameplate data

Explain how a VFD rectifies, filters and inverts to produce variable voltage and frequency, and what the DC bus does

Calculate motor full-load current, overload setting and short-circuit protection sizing from nameplate horsepower and voltage

Compare across-the-line, soft-start and VFD starting methods by inrush current and mechanical stress

Identify VFD-related issues including harmonics, reflected wave on long motor leads and carrier-frequency noise

Diagnose a motor that trips on overload using a structured sequence of current, insulation resistance and mechanical checks

Interpret VFD fault codes such as overcurrent, ground fault and DC bus undervoltage and state the likely root cause of each

Explain how to perform and read an insulation resistance test and what minimum values indicate acceptable winding condition

Describe vibration and thermography as predictive tools and what each detects early in a failing motor or drive

Convert between 4-20 mA, voltage and engineering units for a linear transmitter and calculate the mA value at a given process reading

Explain the difference between two-wire, three-wire and four-wire transmitters and how loop power is supplied

Describe how RTDs and thermocouples work and select the appropriate sensor for a given temperature range and accuracy need

Identify sources of measurement error including lead resistance, cold-junction compensation and grounding-induced noise

Explain how a pressure transmitter measures level in a tank and what reference-leg compensation requires

Trace a 4-20 mA signal from field transmitter through input card to PLC scaling and show the resulting engineering value

Write and interpret ladder logic for start-stop sealing circuits, interlocks and a simple alarm with delay

Explain PLC scan cycle order and predict how input timing and program order affect an output

Describe how analog input modules scale raw counts and configure one for a 4-20 mA range

Distinguish discrete from analog I/O and identify wiring and isolation considerations for each

Develop a systematic PLC troubleshooting approach that separates field device, wiring, I/O module and program faults

Use forcing, monitoring and cross-reference tools safely and explain the risk of leaving forces enabled

Describe preventive maintenance tasks for a control cabinet including thermal inspection, terminal torque checks and backup verification

Explain how to verify a program backup and restore it to a replacement processor

Identify reliability metrics such as MTBF and MTTR and how they guide maintenance prioritization

Review lockout/tagout and energized-work principles and state the conditions under which each applies

Recite the key code requirements for conductor ampacity, overcurrent protection, grounding and motor circuits without notes

Complete a timed mixed-domain practice set and log every missed question by domain and cause

Re-derive the five calculations most often missed in weeks 1 through 6 from memory

Build a personal one-page formula and reference sheet covering power, motor current, loop scaling and fault current