Category Definitions

The MACIES data collection focuses on all major instrumentation categories within Process Industries, definitions and examples for each category are given below. Please study these definitions in conjunction with the MACIES Data Submission Rules and MACIES Industry Definitions before completing any data collection forms.

Note that discontinued category numbers have been deleted without changing the numbering of the remaining categories to maintain consistency of reporting.

Please contact Scott Pepper or Helena Robinson with any questions.

 

General Guidance


  • Process instrumentation will typically have some level of certification/approval for use in process environments, including but not lmited to the below. Equipment with none of these is unlikely to be considered suitable for process control applications.
  • Smart devices are equipped with microprocessors and are capable of digital communications, including HART, PROFIBUS PA/DP or FOUNDATION Fieldbus. Smart devices have advanced diagnostic capabilities and often allow signal compensation and conditioning or self-calibration, all with the aim of making the instrument more accurate, repeatable and reliable. Products which fit the definition should be classified as ‘smart’ whether or not the capability is being used.
  • Where high value mountings or process connections are sold with transmitters, these should be separated out to the contributor's best ability.

 

Product Category Definitions


(Please click the category title to open each of the definitions below)

Pressure

1.1 - Transmitters

Transmitters which respond to a measured variable by means of a basic sensing element, and convert it to a standard transmission signal (e.g. 4 to 20 mA/0 to 20 mA, digital), which is a function of the measurement, and can be physically separate from the receiving instrument. The transmitter may be used to measure pressure directly or flow indirectly (transmitters used to measure level are included in 3.5).

Note: Include wireless in each category as a percentage of units.

  1. Pressure and Absolute Pressure

    Excluded are: P/I converters

    1. Fixed span devices

      examples

    2. Rangeable devices
      1. Smart

        examples

      2. Non-smart

        examples

  2. Differential Pressure
    1. Rangeable devices; non-smart & smart

      Excluded are: Flanged versions for level measurement – See 3.5

      examples

  3. Multivariable Pressure

    A dedicated transmitter that measures differential pressure, static pressure and incorporates or allows input of a process temperature measurement to allow the calculation of mass flow.

    examples

1.3 - Pressure Switches

A pressure-sensing device with a switched output. Both mechanical and electrical switches may be included.

examples

Temperature

2.1 - Head Mounted

Commonly refer to as "Hockey Pucks" due to their shape, head-mount temperature are small disc shaped transmitters that are often mounted within a connection head. The connection head is usually attached directly to the sensor; but, can be located remotely. Only self-contained head mounted transmitters are to be included. An input device being an integral part of a control system is not to be reported in this category.

Thermowells and ancilliary equipment should not be included in these figures.

Note: Include wireless in each category as a percentage of units.

examples

2.2 - Field Mounted

Field-mount temperature transmitters are designed with a dual compartment housing that keeps moisture, humidity, or other contaminants from getting into the transmitter's electronics. Only self-contained field mounted transmitters are to be included. An input device being an integral part of a control system is not to be reported in this category.

Thermowells and ancilliary equipment should not be included in these figures.

Note: Include wireless in each category as a percentage of units.

examples

2.3 - Panel or Rack Mounted

Panel-mount (also called rack-mount or rail-mount) temperature transmitters are designed to be mounted on DIN-rails located in non-harsh environments usually in or near control rooms. Only self-contained panel mounted transmitters are to be included. An input device being an integral part of a control system is not to be reported in this category.

Thermowells and ancilliary equipment should not be included in these figures.

Note: Include wireless in each category as a percentage of units.

examples

Level

3.1 - Ultrasonic Level Transmitters & Systems

A transmitter or combination of transducer and control unit utilising the time of flight of ultrasonic sound through the ullage space above a medium to determine the level of the medium. This time of flight is converted into an output signal proportional to level or contents.

Note: Transmitters or systems for open-channel flow applications are included in this category (prior to 2021 these were reported in 6.7)

  1. Ultrasonic Level Transmitters – liquid and dry product

    examples

    Also includes: Open channel ultrasonics for flow

     

    examples

3.2 - Microwave Level Transmitters (Radar)

  1. Non-contacting Radar Transmitters (excl. Inventory Tank Gauging)

    A transmitter or combination of antenna and control unit utilising time of flight of microwave signals through the ullage space above a medium to determine the level of the medium. This signal is converted to an output signal proportional to level or contents. Excluded are Inventory Tank Gauging (ITG) transmitters.

    examples

  2. Inventory Tank Gauging Radar Transmitters

    A transmitter or combination of antenna and control unit for use specifically in Inventory Tank Gauging applications utilising time of flight of microwave signals through the ullage space above a medium to determine the level of the medium. This signal is converted an output signal proportional to level or contents.

    examples

  3. Guided Wave Radar (GWR) and Time Domain Reflectometry Radar (TDR)

    A transmitter utilising the change in dielectric constant between two media to reflect part or all of a microwave pulse transmitted along a guide wire or rod. The return journey time of the pulse is used in calculations by the transmitter to determine the level of a liquid or dry product medium, or the interface between two liquid media, and to give an output signal proportional to level or contents.

    examples

3.3 - Capacitive Level Transmitters

A transmitter utilising the change in capacitance associated with the difference in dielectric constant between two mediums to determine the level of a liquid or dry product medium and to give an output signal proportional to level or contents.

examples

3.5 - Stand Alone Hydrostatic Sensors / Transducers or Pressure Transmitters for Measuring Level

A transmitter that has been modified or designed for mounting in or at the bottom of a tank of liquid and which contains a sensing element which measures the force exerted by the head of the liquid. The output of the device, digital, analogue or pneumatic, from either integral or remote signal conditioning is proportional to the head of liquid in the tank.

examples

3.6 - Level Switches

A level-sensing device with a switched output.

  1. Liquids

    e.g. Float / Reed switches, Capacitive switches, Vibrating Fork switches, Conductivity switches.

    examples

  2. Solids

    e.g. Paddle switches, Vibrating Fork or Rod switches, Capacitive switches.

    examples

Flow and Density Measurement

6.1 - Electromagnetic Flowmeters

Electromagnetic flow meters, or magmeters, are comprised of a transmitter and sensor that together measure flow. The magnetic flow meter’s sensor is placed inline and measures an induced voltage generated by the fluid as it flows through a pipe. The transmitter takes the voltage generated by the sensor, converts it into a flow measurement and transmits that flow measurement to a control system.

Sensor and transmitter, whether integrally or separately mounted, should be reported as one unit.

examples

6.2 - Coriolis Mass Flowmeters

A Coriolis flow meter contains a tube which is energized by a fixed vibration. When a fluid (gas or liquid) passes through this tube the mass flow momentum will cause a change in the tube vibration, the tube will twist resulting in a phase shift. This phase shift can be measured and a linear output derived proportional to flow.

Sensor and transmitter, whether integrally or separately mounted, should be reported as one unit.

examples

6.3 - Vortex Meters (excluding domestic)

Vortex meters utilise the Von Karman effect to measure fluid velocity. A dimensioned bluff/shedder bar is used to generate vortices, the frequency of these oscillating vortices is converted into fluid velocity and, along with the meter flow area, volumetric flow can be calculated.

Sensor and transmitter, whether integrally or separately mounted, should be reported as one unit.

examples

6.4 - Dedicated Density Measurement

Instrumentation technologies used to determine the density of a process fluid. Density measurements are often used to measure product quality, perform conversions between mass and volume or identify product interfaces. These measurements are needed anywhere that fluid value, quality or composition is important.

  1. Dedicated Density Measurement - Liquid

    Density meters used for measuring density of liquids only. Includes all density measurement techniques including vibration, nucleonic and microwave.

    examples

  2. Dedicated Density Measurement - Gas

    Density meters used for measuring density of gases only. Includes all density measurement techniques including vibration, nucleonic and microwave. Specific gravity meters should be included here

    examples

6.6 - Variable Area

Variable area flow meters are realatively simple devices that operate at a relatively constant pressure drop and measure the flow of liquids, gases, and steam. The position of their float, piston or vane is changed as the increasing flow rate opens a larger flow area to pass the flowing fluid. The position of the float, piston or vane provides an indication of flow rate. Design variations include the rotameter, orifice/rotameter combination, open-channel variable gate, tapered plug, and vane or piston designs.

Variable area flow meters provide a visual indication of flow and may also incorporate a transmitter to provide an analogue or digital signal output.

Category 6.6 includes all of the following:

  • Variable Area - Metal
    • Without transmitters

      examples

    • With transmitters

      examples

  • Variable Area - Glass

    examples

6.7 - Ultrasonic

Ultrasonic flowmeters utilise sound waves to determine the velocity of a fluid flowing in a pipe and use this to calculate the flow rate. Included are transit time (or time of flight) and Doppler ultrasonic flow meters.

Note: Include wireless as a percentage of units.

  1. Closed pipe
    1. Utilising wetted transducers mounted in a spoolpiece

      examples

    2. Non-invasive: utilising clamp-on transducers
      1. Liquid

        examples

      2. Gas

        examples

6.8 - Thermal Mass Flowmeters and Controllers

Thermal Mass Flow Meters or Controllers which utlise the heat conductivity of fluids to provide a direct measurement of mass flow.

Category 6.8 includes all of the following:

  • In-line type up to and including 1/2"

    examples

  • In-line type over 1/2"

    examples

  • Insertion type

    examples

Notes:

  1. Include wireless as a percentage of units.

Converters

7 - Converters (I/P & P/I) Smart and Non-smart

Current to pressure converters (I/P) converts an analog signal (4-20 mA) to a proportional linear pneumatic output (3-15 psig). Also include pressure to current (P/I) converters.

examples

Analytical Instruments - Liquid

9L a - Sensors / Probes - Dissolved Oxygen

Probes for determining the amount of oxygen dissolved or carried in a process liquid. Included are all measurement techniques, including polographic, galvanic and optical.

Note: Only sensors and probes to be included, transmitters should be included in category 9L f) or 9L g).

examples

9L b - Sensors / Probes - Suspended Solids (incl. turbidity)

Probes for determining the solids content and turbidity in water, wastewater, and industrial process applications.

Note: Only sensors and probes to be included, transmitters should be included in category 9L f) or 9L g).

examples

9L c - Sensors / Probes - Chlorine

Probes for determining free chlorine, chlorine dioxide or total chlorine content of liquids.

Note: Only sensors and probes to be included, transmitters should be included in category 9L f) or 9L g).

examples

9L d - Sensors / Probes - pH and ORP

Probes for determining the pH or oxidation reduction potential (ORP) of a liquid.

Note: Only sensors and probes to be included, transmitters should be included in category 9L f) or 9L g).

examples

9L e - Sensors / Probes - Conductivity

Probes for determining the conductivity of a solution. Includes all measurement methods, including contacting and inductive.

Note: Only sensors and probes to be included, transmitters should be included in category 9L f) or 9L g).

examples

9L f - Transmitters - Single Channel

Transmitters for use with analytical sensors and probes capable of transmitting a single variable. All specialist single variable transmitters should be included here.

examples

9L g - Transmitters - Multi-Channel

Transmitters capable of outputting multiple channles, for use with analytical sensors and probes. All multi-channel transmitters should be included even if the capability has not been used.

examples

Note: Liquid Analytical categories have been modified for MACIES 2020.

Analytical instruments should now be split into probes/sensors and transmitters as per the above definitions.

For systems which include a sensor and transmitter combination these should be split to the contributor's best ability to avoid high value systems skewing figures in either category.

For systems which include ancillary equipment such as sampling systems, high value/retractable process connectors, mounting systems etc. these should also be separated to the contributor's best ability to avoid high value ancillary equipment skewing figures in either category. The cost of ancillary equipment may be estimated as part of the supplementary collection (discussed previously as 'Uplift Factors').

 

Analytical Instruments - Gas

9G f - NIR Analysers

Online analysers which utilise electromagnetic spectrum wavelengths between 700nm and 2500nm (near-infrared region).

examples

9G g - Gas Chromatograph Analysers - Process & Flue

Process gas chromatographs used for separating and analyzing chemical compounds in the gas phase of industrial processes.

examples

9G k - Oxygen Analysers

Analysers for measuring Oxygen content of process gases which are often used in combustion control, process quality, safety and environmental applications. All measurement techniques excluding TDL analysers (which should be included in 9G l) should be included. Products should be split by the analyser's target concentration measurement:

  1. For % analysis

    examples

  2. For ppm trace analysis

    examples

9G l - Laser (TDL) Analysers

Tunable Diode Laser (or TDL) analysers utilise a spectroscopy technique measuring the amount of laser light that is absorbed (lost) as it travels through the gas being measured. TDL analysers are capable of detecting a variety of gases, all TDL analysers should be included here.

examples

Control Systems

10.1 - Distributed Control Systems - Hardware

All physical hardware supplied as part of a control system and any firmware integrated into that hardware. This includes I/O controllers, control room cabinets, power supplies, workstations, switches etc.

Value only to be collected.

10.2 Distributed Control Systems - Software

All software packages supplied as part of a control system. This includes software for fundamental control, human machine interfaces (HMI), systems and alarm management, engineering and configuration, data historian, cybersecurity etc.

Value only to be collected.

10.3 - Distributed Control Systems - Project Services

All engineering, configuration and project engineering services.

Value only to be collected.

10.4 - Distributed Control Systems - Operations Services

All maintainence and operational support services.

Value only to be collected.

10.7 - Supervisory Control and Data Acquisition Systems (SCADA)

All hardware or software assocaited with the supply of SCADA systems.

Value only to be collected.

Recorders

11.5 - Parerless Recorders

Devices recording signals, including electrical, temperature, etc. measurement. Included are data recorderers providing the ability to capture continuous and batch data electronically in a secure digital format. ​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​ Also includes recorders with, or without, control or alarm features.

 

Positioners

15 - Control Valve Positioners

  1. Control Valve Positioners - Smart

    As well as accurately controlling the position of the control valve and auto-calibrating, a smart positioner can also communicate with the DCS to provide data such as position, pressure and also relay some diagnostic information or fault status.

    Notes: Include wireless as a percentage of units.

Wireless Adapters & Infrastructure

16.1 - Wireless Adapters (stand alone)

Stand alone, self-contained wireless adaptors for use in conjunction with any instrument, including both battery and wired power, with integrated transceiver and aerial, typically operating at 2.4 GHz and using a wireless protocol to transmit a process variable or variables.

16.2 - Wireless Gateways and Repeaters

Wireless gateways and other wireless enabling infrastructure required to allow wireless instruments to connect to an industrial control system. All capacity gateways should be included as well as wireless signal repeaters.

Instrument Services

19 - Instrument Services

To include revenue from process instrumentation services (excluding DCS/Systems services), including:

  • Installation & Commissioning
  • Calibration
  • Maintainence & Repair (excl. parts)
  • Design and testing services
  • Training