Upstream (production) processes typically operate at 100bar and 150C. Processes range from drilling, through recovery and separation and offloading of liquid or gas fractions. Environments are harsh, and instrumentation will typically have both SIL and ATEX ratings to meet safety and explosive atmosphere protection.

Midstream refers to pre-processing, storage and distribution which can occur on floating facilities and land based receiving stations. Temperatures and pressures tend to be less than upstream levels but ATEX and SIL still apply. Note that tank level measurement tends to be more prolific in these areas along with density measurements and more specific areas of radiometric based instruments.

Instrument materials will typically be high quality steels. Additional outputs from the instruments will include HART or similar.

Instrumentation will typically have third party certification from organisations including BV, Lloyds or ABS.

For the purposes of MACIES, Chemicals are defined as non-organic. Wet chemicals will focus on areas including Acid/Alkali production whilst dry chemicals focus on pigments, coatings, cement and fertilizers. Purification of feedstock into, for example, the microprocessor industry, would also fit into this area.

Instrumentation will be required to operate in adverse conditions, particularly where acid/alkalis exist or can operate in explosive atmospheres.

Chemically resistant materials will be key to the body of the instrument. Additional outputs from the instruments will include HART or similar.

Fine chemicals, producing feedstock for use in the pharmaceutical industry as also included in this category.

The petrochemical industry, downstream processing, includes all areas from simple cracking plants for the production of liquid and gaseous fuels through to complex processing of organic chemicals.

All these areas are potentially explosive and operate in hostile, high temperature and pressure environments. The full range of suitably protected instrumentation operates in these areas.

Instrument materials will typically be high quality steels. Additional outputs from the instruments will include HART or similar.

Pulp and paper process include digester controls, fibre lines, oxygen delignification, bleaching and wet end preparation. Additional less instrumented processes will include the forming, cutting, drying and packing of the various webs, i.e. the dry side of the process.

All standard types of instruments are applied within the processing (P, T, L) with additional instruments for pH, conductivity plus specific systems for measuring fibre distribution. All instrumentation would be considered rugged.

Some parts of the process are hazardous, while the majority operate at atmospheric pressures and temperatures up to 150C.

Food and beverage processes, i.e. those subject to process controls, include; sugar, dairy, brewing and soft drinks. Included are the packaging and bottling lines directly associated with the products.

Hygiene is critical and thus any instrument in contact with product must be suitable for CIP (Clean in Place) processing, often a caustic environment. Temperatures and pressures are not typically high (1-2bar and <150oC) but materials are important in that they must not degrade or taint the product.

Process issues include foaming thus any instrument must be suitable for its environment.

Particularly in brewing, level measurement and metering of dry feedstock at the front end of the process will be included. Similarly, for soft drinks where the feedstocks are predominantly liquids plus water.

Life Scinces includes pharmaceutical and biotechnology manufacturing and covers both wet and dry feedstocks and their measurements through both chemically and biologically active substances that result in dry (powder/pill) or liquid end products.

The environments are highly regulated and sterile thus all instruments will require high levels of accuracy and certification especially where dosage is key, and the ability for use not just in control but in data production, hence it would be expected that HART or similar enabled hardware is standard.

Finishing lines (tablet/capsule and bottling production) would be included in the process section of this exercise and in many cases, is completed at different facilities.

All the standard instrumentation is utilised (P, L, F, T) along with analytics, weighing and analysis systems. Operating conditions are not physically harsh (<150oC and < 2 bar) whilst packaging is with high quality materials a key part.

Process control in fossil and nuclear power plant is generally around the prime and secondary energy source, i.e. fuel stock and steam raising/boiler controls and balance of plant. Distribution can be excluded as this mainly looks at breaker control and load sharing.

Instrumentation will include temperature, pressure and flow and these units will operate at high temperatures and pressures in steam raising equipment. Normal conditions will be recorded at atmospheric conditions e.g. water flows.

Water and wastewater industry are a major user of instrumentation and typically use devices from the middle of the performance spectrum. Much of the instrumentation is required for data analysis. However, where process control is required, the solutions need to meet regulatory requirements hence the areas of sludge combustion, flow metering, dosing, tank levels and analysers will require high quality instruments.

MCERTS are a common requirement in this industry, relating to outfalls.

Environmental monitoring covers instrumentation that is typically analytical rather than process based. The analysis is aimed at the control of effluent from industry including power stations, petrochemical stacks and water treatment works. Analysis is of fluids and gases, mostly at standard temperatures and pressures. The data is used primarily for reporting but can also be used in feedback loops where the process can be modified or treatment e.g. gas scrubbers can also be controlled.

In the UK, the Environment Agency operate a system of MCERTS where instrumentation is required to meet additional specifications. It is expected that as a minimum, all MCERT equipment would be included in this section.

Firstly, all process instrumentation for use in marine environments will have certification from a suitable body, including DVN, Lloyds, BV etc. Process instrumentation will include bunkering applications for fuel delivery to ships, fuel level onboard ships, emission monitoring equipment and ballast control systems.

Various directives require the accurate recording of fuel bunkering, fuel types, fuel consumption, and emissions monitoring.

Whilst there will be some closed loop control, the majority of instrumentation is required for data recording and as they require certification (as above), these instruments tend to be of higher value and quality.

Glass manufacturing is a continuous process with dry feedstock being measured for weight and flow control and furnaces linked directly into the control loops. The environment is hot whilst there are no undue pressure loops. Instrument products in this industry are standard Level, Temperature and Pressure but need to be of low maintenance as production will be 24/7 and operate for up to 10 years. A system that trips will take time to reinitiate.

Process control looks at the raw material silos, mixing and heating. Cooling water and water treatment are controlled as are the stack emissions.

The forming and stacking systems tend to fall into the industrial process side and thus instrumentation can be ignored from these processes.

Metals and Mining processing is the extraction and primary/ secondary processing of minerals. The activity includes all areas of instrumentation.

Other should be used for industries which fall outside of the above so long as the instrumentation meets the previously specified criteria of process instrumentation. Examples include textiles, automotive etc. For true process industries vendors, we would expect the percentage of others to be small.