COMPLETE REVISION
July 2016
Process Control
PIP PCEIA001
Instrument Air Systems Guidelines
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence
over this Practice. Determinations concerning fitness for purpose and particular matters
or application of the Practice to particular project or engineering situations should not
be made solely on information contained in these materials. The use of trade names
from time to time should not be viewed as an expression of preference but rather
recognized as normal usage in the trade. Other brands having the same specifications
are equally correct and may be substituted for those named. All Practices or guidelines
are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these Practices or guidelines should conflict with OSHA or
other applicable laws or regulations, such laws or regulations must be followed.
Consult an appropriate professional before applying or acting on any material
contained in or suggested by the Practice.
This Practice is subject to revision at any time.
© Process Industry Practices (PIP), Construction Industry Institute, The University of
Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP Member
Companies and Subscribers may copy this Practice for their internal use. Changes or
modifications of any kind are not permitted within any PIP Practice without the express
written authorization of PIP. Authorized Users may attach addenda or overlays to clearly
indicate modifications or exceptions to specific sections of PIP Practices. Authorized
Users may provide their clients, suppliers and contractors with copies of the Practice
solely for Authorized Users’ purposes. These purposes include but are not limited to the
procurement process (e.g., as attachments to requests for quotation/ purchase orders or
requests for proposals/contracts) and preparation and issue of design engineering
deliverables for use on a specific project by Authorized User’s client. PIP’s copyright
notices must be clearly indicated and unequivocally incorporated in documents where an
Authorized User desires to provide any third party with copies of the Practice.
PUBLISHING HISTORY
October 1997 Issued
June 2003 Editorial Revision
July 2011 Complete Revision
July 2016 Complete Revision
Not printed with State funds
COMPLETE REVISION
July 2016
Process Control
PIP PCEIA001
Instrument Air Systems Guidelines
Table of Contents
1. Scope ...........................................2 6. Piping Distribution System ........8
6.1 General............................................. 8
2. References ..................................2 6.2 Piping and Tubing ............................ 9
2.1 Process Industry Practices ...............2 6.3 Valves............................................... 9
2.2 Industry Codes and Standards .........2
7. Testing .......................................10
3. System Design ............................2 7.1 Piping ............................................. 10
3.1 General .............................................2
3.2 System Pressure ..............................3
3.3 Capacity/Sizing .................................3
3.4 Air Quality .........................................3
3.5 Air-sets .............................................4
3.6 Monitoring and Control Systems ......4
4. Equipment ...................................5
4.1 General .............................................5
4.2 Compressors ....................................5
4.3 Intake Air Filters................................5
4.4 Compressor Aftercoolers ..................6
4.5 Air Receivers ....................................6
4.6 Air Dryers ..........................................6
4.7 Air Dryer Prefilters ............................7
4.8 Afterfilters .........................................7
5. Reliability and Availability ..........7
5.1 General .............................................7
5.2 Design Considerations .....................7
5.3 Inert Gas Backup Supply ..................8
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Instrument Air Systems Guidelines July 2016
1. Scope
This Practice provides guidelines for designing instrument air systems that supply pneumatically
actuated instruments and valves. This Practice provides design guidelines for air quality, capacity,
sizing, and testing of instrument air systems.
2. References
Applicable parts of the following Practices shall be considered an integral part of this Practice.
The edition in effect on the date of contract award shall be used, except as otherwise noted. Short
titles are used herein where appropriate.
2.1 Process Industry Practices (PIP)
– PIP PCCIA001 - Instrument Air Systems Design Criteria
– PIP PCCIP001 - Instrument Piping and Tubing Systems Criteria
– PIP PCIIA000 - Instrument Air Installation Details
2.2 Industry Codes and Standards
American Petroleum Institute (API)
– API STD 672 - Packaged, Integrally Geared Centrifugal Air Compressors for
Petroleum, Chemical, and Gas Industry Services
American Society for Mechanical Engineers (ASME)
– ASME - Boiler and Pressure Vessel Code, Section VIII, Division 1
(ISA) The International Society of Automation
– ISA 7.0.01 - Quality Standard for Instrument Air
3. System Design
3.1 General
3.1.1 The instrument air system should be designed to meet the specified pressure,
capacity, and air quality requirements.
3.1.2 The instrument air system should not be cross-connected to any other air system
other than the backup system to prevent cross-contamination.
3.1.3 Instrument air should only be used for pneumatic instrumentation.
3.1.4 Purging Process Connections
3.1.4.1 Provisions should be made to prevent the backflow of process material
to the instrument air system from process connections.
3.1.4.2 Instrument air should not be used for processes that cannot have air or
require an inert gas.
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Instrument Air Systems Guidelines July 2016
3.2 System Pressure
3.2.1 The instrument air header pressure at the air dryer(s) outlet should be a minimum
of 6.9 bar (100 psig).
3.2.2 The instrument air piping distribution system should be sized so that the
minimum pressure at any instrument or device connected to the system is 5.5 bar
(80 psig) when all devices are at maximum air consumption. Typically, the
following air pressures are required for operation of the following
instrumentation types:
a. Pneumatic instrumentation (i.e., transmitters, controllers, recorders):
1.7 to 2.4 bar (25 to 35 psig)
b. Control valve diaphragm actuators: 2.4 to 4.2 bar (35 to 60 psig)
c. Control or On-Off valves with piston actuators: 4.2 to 5.5 bar (60 to 80 psig)
3.2.3 Pressure drop should be accounted for throughout the entire instrument air
system. This should include filters, coolers, drying equipment, and distribution
piping.
3.3 Capacity/Sizing
3.3.1 The minimum capacity of the instrument air system should be based on the total
requirements of all connected loads plus a 20% design allowance.
3.3.2 The following are different methods for determining the total required load:
a. Steady-state use
b. Every load at full capacity
c. Half on / half off
3.3.3 The following should be considered when determining system capacity:
a. Accurate instrument consumption data
b. Panel purges
c. Process purges
d. Future expansion
e. Distribution system leaks
3.4 Air Quality
3.4.1 Instrument air should be free of water, oil, and particulate material. These
contaminates will damage pneumatic instrumentation.
3.4.2 The air quality should be in accordance with ISA 7.0.01.
3.4.3 The dew point as measured at the air dryer(s) outlet should be at least 10°C
(18°F) below the minimum temperature to which any part of the instrument air
system is exposed.
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3.5 Air-sets
3.5.1 A separate air-set should be installed for any pneumatically actuated instruments
or valves that require reduced pressure in accordance with PIP PCIIA000.
3.5.2 An air-set should consist of the following:
a. Direct-operated regulator with integral filter, drip well, drain valve, and
outlet pressure gauge
b. Regulator should have internal pressure relief
c. Filter material of construction should be non-paper
3.5.3 Providing a filter with integral drip well and drain valve should be considered for
pneumatic instruments that require full supply system pressure.
3.6 Monitoring and Control Systems
3.6.1 Selection of monitoring and control systems depends on the type of compressor,
owner preference, instrument air demand cycle, and plant economics.
3.6.2 Control system(s) for instrument air compressors are typically provided by the
compressor manufacturer.
3.6.3 Serial connection(s) may be provided by the instrument air control system(s) for
connection to the plant’s control system.
3.6.4 Dew point should be continuously monitored to assure the proper performance of
the instrument air system. Moisture can cause failure of instruments and valve
actuators.
3.6.5 Anti-surge protection and associated alarms may be provided depending on the
type of compressor utilized.
3.6.6 The following functions may be monitored and alarmed to ensure safe and
reliable operation of the instrument air system and components:
a. Moisture content at each dryer outlet (dew point)
b. Air flow rate
c. Discharge air pressure
d. Header pressure
e. Compressor interstage temperature
f. Compressor oil pressure and temperature
g. Compressor speed (variable speed machines)
h. Compressor vibration
i. Cooling water flow and temperature
j. Manufacturer required alarms
k. Surge protection alarms
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PIP PCEIA001 COMPLETE REVISION
Instrument Air Systems Guidelines July 2016
4. Equipment
4.1 General
4.1.1 This section provides instrument personnel with basic information about the
equipment required for an instrument air system.
4.1.2 Instrument air system equipment should be in accordance with API STD 672 if
applicable.
4.1.3 An instrument air system would typically include some or all of the following
equipment:
a. Monitoring and control systems
b. Compressors
c. Intake air filters
d. Compressor aftercoolers
e. Air receivers
f. Air dryers
g. Air dryer prefilters
h. Afterfilters
4.1.4 All instrument air system equipment should have manual isolation valves for
maintenance and repair.
4.2 Compressors
4.2.1 Compressors should be sized to deliver air at the specified pressure, rated flow,
and maximum ambient temperature.
4.2.2 If lubricated compressors are used, provisions should be made to remove
lubricants from the air discharge.
4.2.3 Common types of compressors used to supply instrument air include the
following:
a. Reciprocating
b. Rotary screw
c. Centrifugal
4.3 Intake Air Filters
4.3.1 Intake air filters are used to remove contaminates from entering the compressors.
4.3.2 Intake air filters should be located away from sources of dirt, moisture, and toxic,
noxious, corrosive, or flammable gases.
4.3.3 Intake air filters should be located at a height to exclude ground level dust and
debris.
4.3.4 Parallel intake air filters should be considered to permit changing or cleaning of
the filters without shutting down the instrument air system.
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4.4 Compressor Aftercoolers
4.4.1 Aftercoolers are used to cool the heated air discharged from the compressor.
4.4.2 Aftercoolers are typically either water or air cooled with an integral separator and
trap to collect and discharge water.
4.5 Air Receivers
4.5.1 Air receivers provide a buffer capacity to the distribution system to handle surges
and disruptions in air usage.
4.5.2 For sizing an air receiver, consideration should be given to the following
conditions:
a. Air reserve needed for system demand surges
b. Capacity for safe and orderly shutdowns
c. Capacity for 90 seconds or greater is typical
4.5.3 Air receivers are constructed in accordance with ASME Boiler and Pressure
Vessel Code, Section VIII, Division 1.
4.5.4 Each air receiver has a properly sized pressure relief device in accordance with
applicable codes.
4.5.5 If freezing temperatures are possible, consideration should be given to freeze
protection for the receiver bottom.
4.6 Air Dryers
4.6.1 Air dryers are used to remove moisture from the compressed air and provide
instrument air at the specified dew point to prevent moisture from damaging
pneumatic instruments.
4.6.2 Common types of air dryers used in instrument air systems include the following:
a. Regenerative desiccant dryers, that use molecular sieves, silica-gel, or
activated alumina
b. Deliquescent dryers
c. Refrigeration dryers, that remove most of the moisture by mechanical
refrigeration, then pass the air through regenerative desiccant
4.6.3 The following information should be obtained when selecting and sizing a dryer:
a. Pressure requirements
b. Flow capacity requirements
c. Air quality requirements
d. Contaminants (e.g., oil, liquid, etc.)
e. Allowable differential pressure drop
f. Provision of filters and degree of filtration
g. Accessories (e.g., pressure gauges, relief valves, thermometers, and safety
switches)
h. Temperature requirements
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Instrument Air Systems Guidelines July 2016
4.7 Air Dryer Prefilters
4.7.1 Air dryer prefilters are used to remove oil vapors before the air dryers.
4.7.2 Common types of prefilters used in instrument air systems include the following:
a. Adsorbent-type oil prefilter
b. Coalescent-type prefilter with continuous drain feature
4.7.3 Parallel air dryer prefilters should be considered to permit changing or cleaning
the filters without shutting down the instrument air system.
4.8 Afterfilters
4.8.1 Afterfilters are used to remove any particulate matter from the dryer discharge.
Particulate matter can damage pneumatic instruments.
4.8.2 Parallel afterfilters should be considered to permit changing or cleaning the
filters without shutting down the instrument air system.
5. Reliability and Availability
5.1 General
5.1.1 Typically, operating processes require high reliability and availability of
instrument air.
5.1.2 Instrument air system design should consider the reliability and availability of
each component (e.g., compressors, air dryers, filters, distribution system).
5.1.3 Methods for improving instrument air system reliability and availability include:
a. Providing multiple compressors, air dryers, and other system components
that permit equipment to be taken out of service for maintenance and repair
without affecting the capacity of the overall instrument air system
b. Portable compressors, air dryers, and other system components that connect
to the system with zero or minimal downtime
c. Compressed air cylinders
d. Bypasses around equipment
e. Parallel filters
f. Backup system(s) for individual instruments, groups of instruments, or entire
system
g. Volume tanks on valve actuators
5.2 Design Considerations
5.2.1 Instrument air system reliability and availability design considerations include:
a. Automatic switching of compressors or dryers
b. Manual switching of compressors or dryers including the time available for
an operator to react to an alarm
c. Alarming
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Instrument Air Systems Guidelines July 2016
d. Maintaining constant pressure on the instrument air supply system
e. Safe shutdown of equipment and processes
f. Backup system capacity
5.2.2 The adequacy of the associated backup system(s) after system expansion should
be evaluated.
5.3 Inert Gas Backup Supply
5.3.1 Inert gas for a backup supply to the instrument air system is not recommended
because of personnel safety concerns.
5.3.2 If an inert gas backup supply is contemplated, the following personnel protection
issues should be considered:
a. Ventilation of areas occupied by personnel
b. Procedures to address personnel exposure to inert gas in confined areas
(e.g., buildings, houses, panels, enclosures)
c. Oxygen deficiency monitoring
d. Alarms to warn instrument air has been switched to the inert gas system
5.3.3 If inert gas backup supply is provided, the effect on purging process connections
should be considered, including the consequence of lower or absent oxygen at the
purge connection on the process.
5.3.4 If an inert gas backup supply is provided, the effect on any instrumentation
connected to the system should be considered (e.g., analyzer systems where
instrument air is used as a calibration or carrier gas).
5.3.5 If an inert gas backup supply is provided, a means of preventing backflow should
be provided. The following backflow prevention methods should be considered:
a. Check valves
b. Manual double block and bleed valves for the instrument air system side
c. Automated double block and bleed valves activated by differential pressure
across the double block and bleed system that separates the inert gas and
instrument air systems
d. Removable spool piece
6. Piping Distribution System
6.1 General
6.1.1 The instrument air piping distribution system is designed by the piping discipline.
The instrument discipline provides the required information for sizing the
system.
6.1.2 Instrument air branch lines should originate from the top of the header to keep
dirt and other contaminate collection on the bottom of the header piping from
going to the instruments.
6.1.3 Headers should be valved and plugged at the ends for future expansion.
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6.1.4 Instrument air piping distribution systems should be inspected and cleaned of
trash, particles, and foreign objects by blow-down with clean, dry air before
being placed in service.
6.1.5 Piping is responsible for all testing and commissioning of the instrument air
piping distribution system.
6.2 Piping and Tubing
6.2.1 The main instrument air header piping is typically NPS 2 and greater depending
on the capacity of the system.
6.2.2 The instrument air sub-headers are typically NPS 1-1/2 and less depending on the
number of instruments being supplied.
6.2.3 The pressure drop through the sub-header piping can become enough to affect
instrument performance when all of the instruments are at maximum air
consumption. See Table 1 for the recommended maximum number of single
pneumatic instruments or valves that can be connected to sub-header by pipe
size.
Table 1 - Recommended Maximum Number of Instruments or Valves
Sub-Header Size Instruments
(NPS) or Valves
1/2 5
3/4 10
1 25
1-1/2 75
6.2.4 Typically 1/2 inch stainless steel tubing is used to feed individual instruments
from the sub-header.
6.2.5 Tubing material of construction should be in accordance with PIP PCCIP001.
6.2.6 Threaded joints in instrument air service should be made using anaerobic
Teflon dispersion sealant. Teflon tape as a substitute should be used only
with owner approval.
Comment: If installed improperly, small pieces of Teflon tape can flake off,
enter the air stream, and create a potential plugging hazard for the
internal components of pneumatic devices.
6.3 Valves
6.3.1 A block valve should be provided for each branch connection at the header.
6.3.2 Spare taps with a valve and plug should be installed on instrument air
sub-headers to permit tie-ins for future instrument installations.
6.3.3 Each air-consuming component should have its own valve for isolating the
component from the air system.
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6.3.4 For instrumentation root valves, quarter-turn ball valves should have an oval
handle or lever handle with locking device, in order to reduce the opportunity for
accidental operation.
6.3.5 A downstream bleed valve should be provided.
6.3.6 See Table 1 for the recommended maximum number of single pneumatic
instruments or valves that can be connected to sub-header by pipe size.
7. Testing
7.1 Piping
7.1.1 Instrument air or inert gas should be used for pressure testing of supply system
and distribution system.
7.1.2 Hydrostatic testing should not be permitted on the instrument air piping
distribution system.
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