COMPLETE REVISION

July 2016

Process Control

PIP PCCIA001
Instrument Air Systems Design Criteria
 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
March 2003 Editorial Revision
July 2011 Complete Revision
July 2016 Complete Revision

Not printed with State funds

 COMPLETE REVISION
July 2016

Process Control

PIP PCCIA001
Instrument Air Systems Design Criteria
Table of Contents
1. Scope ...........................................2
2. References ..................................2
2.1 Process Industry Practices ...............2
2.2 Industry Codes and Standards .........2

3. Requirements ..............................2
3.1 General .............................................2
3.2 System Pressure ..............................2
3.3 Capacity/Sizing .................................3
3.4 Air Quality .........................................3
3.5 Air-sets .............................................3
3.6 Monitoring and Control Systems ......3
3.7 Equipment ........................................3
3.8 Backup Systems ...............................4
3.9 Piping Distribution System ...............4
3.10 Testing ..............................................4

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PIP PCCIA001 COMPLETE REVISION
Instrument Air Systems Design Criteria July 2016

1. Scope
This Practice provides requirements for designing instrument air systems that supply
pneumatically actuated instruments and valves. This Practice describes the requirements for air
quality, capacity, sizing, and testing of instrument air systems.

2. References
Applicable parts of the following Practices, industry codes and standards, and references 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 PCCIP001 - Instrument Piping and Tubing Systems Criteria
– PIP PCEIA001 - Instrument Air Systems Guidelines
– 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. Requirements
3.1 General
3.1.1 The instrument air system design shall meet the specified pressure, capacity, and
air quality requirements.
3.1.2 The instrument air system shall not be cross-connected to any other air system
other than the backup system.
3.1.3 Instrument air shall only be used for pneumatic instrumentation unless approved
by owner.
3.1.4 If owner approves the use of instrument air for purging process connections,
provision shall be made to prevent the backflow of process material to the
instrument air system from the process connections.
3.2 System Pressure
3.2.1 The instrument air pressure at the air dryer(s) outlet shall be a minimum of
6.9 bar (100 psig).
3.2.2 The instrument air piping distribution system shall be sized so that the minimum
pressure at any instrument or device connected to the system is 5.5 bar (80 psig).

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PIP PCCIA001 COMPLETE REVISION
Instrument Air Systems Design Criteria July 2016

3.3 Capacity/Sizing
3.3.1 The minimum capacity of the instrument air system shall be based on the total
required load plus a 20% design allowance.
3.3.2 Future expansion of the instrument air system shall be considered.
3.4 Air Quality
3.4.1 Instrument air shall be free of water, oil, and particulate material.
3.4.2 The air quality shall be in accordance with ISA 7.0.01.
3.4.3 The dew point as measured at the air dryer(s) outlet shall be at least 10°C (18°F)
below the minimum temperature to which any part of the instrument air system is
exposed.
3.5 Air-sets
3.5.1 A separate air-set shall be installed for each pneumatically actuated instruments
or valves that require reduced pressure in accordance with PIP PCIIA000. The
air-set shall meet the instruments or valves manufacturer filtration requirements.
3.5.2 An air-set shall consist of the following:
a. Direct-operated regulator with integral filter, drip well, drain valve, and
outlet pressure gauge
b. Regulator shall have internal pressure relief
c. Filter material of construction shall be non-paper
3.6 Monitoring and Control Systems
The following functions shall be monitored and alarmed:
a. Moisture content at each dryer outlet (dew point)
b. Header pressure
3.7 Equipment
3.7.1 Instrument air system equipment shall be in accordance with this Practice and
API STD 672 if applicable.
3.7.2 All instrument air system equipment shall be capable of being isolated by hand
valves for maintenance and repair.
3.7.3 Compressors shall be sized to deliver air at the specified pressure, rated flow, and
maximum ambient temperature.
3.7.4 If lubricated compressors are used, provision shall be made to remove the
lubricants from the air supply.
3.7.5 Intake air filters shall be located away from sources of dirt, moisture, and toxic,
noxious, corrosive, or flammable gases.
3.7.6 Intake air filters shall be located at a height to exclude ground level dust and
debris.

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PIP PCCIA001 COMPLETE REVISION
Instrument Air Systems Design Criteria July 2016

3.7.7 If an air receiver is required, it shall be sized for a capacity adequate to handle
expected variations in usage and have a minimum residence time of
1-1/2 minutes (90 seconds) at the rated compressor capacity.
3.7.8 Air receivers shall be constructed in accordance with ASME Boiler and Pressure
Vessel Code, Section VIII, Division 1.
3.7.9 Each air receiver shall have a properly sized pressure relief device in accordance
with applicable codes.
3.7.10 Each air receiver shall be provided with a drain for removal of liquids.
3.8 Backup Systems
The use and design of a backup system(s) shall be approved by the owner.
3.9 Piping Distribution System
3.9.1 Instrument air branch lines shall originate from the top of the header.
3.9.2 Headers shall be valved and plugged at ends for future expansion.
3.9.3 The instrument air piping distribution system shall be inspected and cleaned of
trash, particles, and foreign objects by blow-down with clean, dry air before
being placed in service.
3.9.4 Tubing material of construction shall be in accordance with PIP PCCIP001.
3.9.5 A block valve shall be provided for each branch connection at the header.
3.9.6 Spare taps with a valve and plug shall be installed on instrument air sub-headers
to permit tie-ins for future instrument installations.
3.9.7 Each air-consuming component shall have its own valve for isolating the
component from the air system.
3.9.8 For instrumentation root valves, quarter-turn ball valves shall be provided that
have an oval handle or lever handle with locking device, in order to reduce the
opportunity for accidental operation.
3.9.9 A downstream bleed valve shall be provided.
3.10 Testing
3.10.1 Instrument air or inert gas shall be used for pressure testing of supply system and
distribution system.
3.10.2 Hydrostatic testing shall not be permitted on the instrument air piping
distribution system.

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