Module 1 — Mathematics Fundamentals for Instrumentation

Lesson Topics

1. Engineering mathematics overview
2. Numbers, fractions and decimals
3. Ratios and proportions
4. Percentages and percentage error
5. Units and engineering dimensions
6. SI units and unit conversions
7. Scientific notation
8. Significant figures
9. Engineering notation
10. Rearranging engineering formulas
11. Basic algebra
12. Simultaneous equations
13. Graphs and interpretation of trends

Instrumentation Applications

• Transmitter range calculations
• Instrument accuracy
• Percentage error
• Calibration calculations
• 4–20 mA scaling
• Engineering-unit conversions
• Sensor output calculations

Practical Assignment: Calculate instrument errors, ranges, spans, and scaled 4–20 mA outputs.

Quiz: 15 questions

Module 2 — Geometry, Trigonometry & Vectors

Lesson Topics

1. Angles and degrees
2. Radians
3. Basic geometry
4. Right-angle triangles
5. Pythagorean theorem
6. Sine, cosine and tangent
7. Inverse trigonometric functions
8. Basic vectors
9. Vector addition
10. Resolving forces into components

Instrumentation Applications

• Flow measurement
• Mechanical linkage systems
• Valve actuator movement
• Position measurement
• Pressure and force applications
• Instrument installation geometry

Practical Assignment: Solve basic industrial measurement and mechanical-position problems.

Quiz: 15 questions

Module 3 — Calculus Fundamentals for Instrumentation

Lesson Topics

1. Introduction to calculus
2. Functions and variables
3. Limits
4. Understanding rate of change
5. Derivatives
6. Basic differentiation rules
7. Derivatives of common functions
8. Engineering interpretation of derivatives
9. Integration fundamentals
10. Basic integration rules
11. Definite and indefinite integrals
12. Area under a curve
13. Introduction to differential equations
14. First-order dynamic systems

A useful way to understand derivatives in instrumentation is as rate-of-change, for example how quickly temperature or pressure changes with time.

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Instrumentation Applications

• Temperature rate-of-change
• Pressure dynamics
• Flow accumulation
• Tank level dynamics
• Process response
• Control-system dynamics
• PID control concepts
• Sensor response

Practical Assignment: Analyze a changing process variable and determine its rate of change.

Quiz: 20 questions

Module 4 — Physics Fundamentals for Instrumentation

Lesson Topics

1. Introduction to industrial physics
2. Mass, weight and density
3. Force
4. Pressure
5. Work and energy
6. Power
7. Heat and temperature
8. Specific heat
9. Thermal expansion
10. Fluid fundamentals
11. Hydrostatic pressure
12. Fluid flow fundamentals
13. Viscosity
14. Buoyancy
15. Mechanical equilibrium

Instrumentation Applications

• Pressure transmitters
• Differential pressure measurement
• Level measurement
• Flow measurement
• Temperature measurement
• Load cells
• Force measurement
• Tank and vessel measurement

For example, pressure measurement is fundamentally based on the relationship between force and area:

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Practical Exercises

• Calculate hydrostatic pressure
• Calculate pressure from force and area
• Calculate tank level from differential pressure
• Determine density from mass and volume

Quiz: 20 questions

Module 5 — Heat, Temperature & Thermal Physics

Lesson Topics

1. Heat versus temperature
2. Temperature scales
3. Celsius, Fahrenheit and Kelvin
4. Heat transfer
5. Conduction
6. Convection
7. Radiation
8. Thermal expansion
9. Specific heat capacity
10. Temperature measurement principles
11. RTDs
12. Thermocouples
13. Thermistors
14. Temperature transmitters

Instrumentation Applications

• RTD temperature measurement
• Thermocouple measurement
• Temperature transmitters
• Furnace temperature monitoring
• Boiler instrumentation
• Heat exchanger monitoring
• Process temperature control

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Practical Assignment: Compare RTD and thermocouple measurement systems and calculate basic temperature relationships.

Module 6 — Chemistry Fundamentals for Instrumentation

Lesson Topics

1. Introduction to industrial chemistry
2. Matter and its properties
3. Elements and compounds
4. Atoms and molecules
5. Atomic structure
6. Periodic table fundamentals
7. Chemical bonding
8. States of matter
9. Gases and gas properties
10. Liquids and solids
11. Density and specific gravity
12. Solutions and mixtures
13. Concentration
14. Acids and bases
15. pH
16. Chemical reactions

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Instrumentation Applications

• pH measurement
• Conductivity measurement
• Gas analyzers
• Oxygen analyzers
• Hydrocarbon analyzers
• Process analyzers
• Density measurement
• Chemical dosing systems

Practical Assignment: Calculate concentration, density, specific gravity and basic pH-related instrumentation requirements.

Module 7 — Industrial Chemistry & Process Analyzers

Lesson Topics

1. Industrial process chemistry
2. Hydrocarbon fundamentals
3. Natural gas composition
4. Combustion chemistry
5. Oxygen measurement
6. CO and CO₂ measurement
7. Hydrogen sulfide fundamentals
8. Moisture measurement
9. pH and conductivity
10. ORP fundamentals
11. Gas chromatography overview
12. Analyzer sampling systems
13. Analyzer calibration
14. Analyzer troubleshooting

Industry Applications

• Natural gas processing
• Refinery operations
• Petrochemical plants
• Power plants
• Water treatment
• Environmental monitoring

Practical Assignment: Develop a basic analyzer measurement loop from process sample point to control system.