Instrument Air

A BeaconMedæs Continuing Education Publication

A company within the Atlas Copco Group

 Notes
Notes on Using this Pamphlet:
This pamphlet is presented to assist an engineer or medical facility contemplating the installation of an Instrument Air
system as countenanced under the NFPA 99 Healthcare Facilities standard, 2005 version.

Users are cautioned that this pamphlet is intended to be used in conjuction with the standard, which should be
obtained from:

National Fire Protection Association

1 Batterymarch Park
Quincy, MA 02269-9101
Phone 1-800-344-3555
Internet www.NFPA.org

Users are cautioned to read the pamphlet and the standard carefully, and are encouraged to use the information
herein as suited to the conditions of their project, where such modification does not conflict with applicable local
standards.

This pamphlet only encompasses the requirements of the NFPA 99 through the 2005 version. Please contact
BeaconMedaes to ensure you are using the most recent version of this pamphlet.

Any opinions expressed and/or interpretations given or implied are the sole responsibility of BeaconMedaes, and
should not be relied upon without reference to the NFPA 99 standard and Local Authorities Having Jurisdiction.

This edition August 2006

No Previous Editions

Comments on this booklet or on any aspect of medical gases are welcome and encouraged. Please send to mallen@
beaconmedaes.com

This Pamphlet in both print and electronic versions is Copyright 2006 BeaconMedæs. All Rights are Reserved, and
no reproduction may be made of the whole or any part without permission in writing. Distribution of the Electronic
version is permitted only where the whole is transmitted without alteration, including this notice.

Instrument Air Page 

Table of Contents
Pneumatic power and medicine ………………….… 2
The purpose and the history of Medical Support gases.
Why Change ……………………………………….… 3
Why consider instrument air in lieu of Nitrogen?
Dollars and Cents …………………………….…… 4
How to estimate the economics of an instrument air
system.
NFPA Rules for Instrument Air …………………….… 4
What is an instrument air system and what are the
requirements as found in the standard.
Design and installation …………………………….… 8
Design issues with instrument air pipelines.
Change of Use …………………………………….… 11
Converting nitrogen pipelines to run instrument air.
Page 
Abstract
The paper reviews the background of the most recent
addition to NFPA’s piped gas systems and discusses
when the use of Instrument Air might be appropriate.
Also reviewed are the rules for the application. Design
guidance is provided to allow a system to be sized and
implemented.
Pneumatic power and Medicine
Medical facilities are very familiar with compressed air. A
typical facility uses any number of individual air systems
for power and control. These are as diverse as the laundry
compressor for running the washers and dryers, a sterilizer
compressor for the autoclaves and decontamination systems
in central sterile supply and the HVAC compressor for the
pneumatic controls in the air conditioning system.
Given how familiar hospitals are with compressed air, it
seems odd that most North American hospitals of any size
supply nitrogen into the operating rooms to run surgical
tools - a task easily within the capabilities of an appropriate
compressed air system.
Compressed air systems require only occasional
maintenance, the air is of course free, and there is no
management required. By comparison, the nitrogen
system is an unending hassle. The nitrogen is in cylinders
or containers which must be purchased, inventoried, and
changed. Since hustling the cylinders or containers is labor
intensive, there is always an overhead in costs and labor
associated with its use.
Although the nitrogen system could be used for many
purposes per the NFPA standard, the nitrogen gas is
relatively expensive so it is not wise to use it for all the
applications for which it might otherwise be appropriate.
This leaves a quandary when the facility wants pneumatic
power in places like the morgue or central sterile supply.
Often the unsatisfactory solution is to install separate local
systems, which is expensive and increases the maintenance
burden.
Compressed air was in fact the original choice when gas
- powered tools first came into the operating room, and
only in North America was compressed air supplanted by
Nitrogen. The reason for this decision is obscured by time,
but most likely derives from difficulties with the quality of
the air available at the time. Piped air was typically wet,
often oily and sometimes dirty, none of which is good
for high speed turbine tools. Nitrogen was the driest,
cleanest gas they could easily substitute, so it became
the gas of choice. Over time, primarily through received
knowledge, it acquired the patina of a de facto standard.
In fact, Nitrogen for tools has never been required by any
Instrument Air
published standard. Nevertheless, Engineers continue even
today to design, and facilities continue to install, nitrogen
systems for the driving of surgical tools.
In most of the world, compressed air never left the O.R. In
the United Kingdom for instance, it is common to install
a “7 bar” or “13 bar” surgical air system specifically for
driving tools alongside the “4 bar” medical air for treating
patients.
There is a vestigial holdover from the use of compressed
air for surgical tools in use in North America even today.
Surgical tool hoses are still often fitted with a quick
connect fitting on the end called a “Schræder” connector
- originally manufactured by the Schræder Automotive
Division, and used in garages to run their air-powered
tools (the historic origin of our elegant surgical tools is not
medical, but industrial).
Oddly, although the pipelines changed from air to nitrogen,
Schraeder never did make the change. Even today the
version of that connector in most common use is stamped
“Air” - Schræder itself never made a nitrogen-specific
connector, and only very recently have their successor
companies created one.
Although Nitrogen systems have become the general
standard, there have always been a small number of North
American facilities willing to question this. These facilities
have installed air systems to drive tools, following their own
instincts in light of an absence of guidance in the NFPA
or CSA standards. The trend has accelerated somewhat
in the last decade, and in the 2002 edition NFPA for the
first time included guidance on these systems. Although
that might make it seem to be something new, in truth it is
actually a return to something very old.
When the Instrument Air system first appeared in the 2002
NFPA 99, there was no Instrument Air terminal unit, and
thus no outlets, controls or hoses were available. This
was a problem which prevented many facilities from
seriously looking at the Instrument Air option. In 2005,
the Compressed Gas Association resolved this with the
assignment of the CGA 2080 connection to Instrument Air.
The only remaining hurdle therefore is the lack of design
guidance, which this publication should help address.
Why Change?
There are two reasons to consider an Instrument Air system,
and it is important to note that neither is specifically
medical. In fact, from the medical standpoint, there is very
little to choose between Instrument Air and nitrogen. Both
will drive the tools, both (as contemplated by NFPA 99)
have similar dryness, cleanliness, and operating pressures.
Except for the costs involved, there is no reason a facility
could not simply continue to use nitrogen.
Instrument Air
So the most compelling reason to consider an Instrument
Air system over a Nitrogen system is dollars and cents.
The cost of operating a nitrogen system can be surprisingly
high, depending on the amount of nitrogen used. Nitrogen
sources imply three particular costs:
1. The cost of the gas itself.
2. The cost of the demurrage (rental of the cylinders).
3. The management cost, including the labor involved in
hustling the cylinders from the dock to the manifold,
attaching and detaching them, and moving the
empties back to the dock, plus the management
involved in keeping track of cylinder inventories and
reordering).
While it is possible to reduce these costs in many cases by
using cryogenic liquid in place of gas cylinders, the costs
are never completely eliminated, and the installation of
a large cryogenic source system may be problematic in
other ways.
Generally speaking, an Instrument Air system is going to
be more expensive to purchase than a similar capacity
manifold or bulk liquid system. However, the Instrument
Air itself is less costly on a volume to volume basis, so
the Instrument Air system will pay for itself over time.
Exactly when the crossover will occur will vary. In some
cases, the crossover may be so far out that an Instrument
Air system would be a questionable investment. In other
cases the payback is so quick that Instrument Air would be
worth retrofitting even where a nitrogen system is already
in place. In the next chapter entitled “Dollars and Cents”,
we give some guidance on how to calculate the crossover
point for your facility.
The other reason for considering Instrument Air is the
variety of applications for which it can be used. NFPA has
continuously sought to keep medical gas systems separate
from all other systems and to ensure that the medical gases
are not compromised by use for other purposes. NFPA 99
2005 5.1.3.4.2 states “Central supply systems for oxygen,
medical air, nitrous oxide, carbon dioxide and all other
patient medical gases shall not be piped to, or used
for, any purpose except patient care application”. The
practical effect of this prohibition is found in the Annex
A.5.1.3.4.2 “Prohibited uses of medical gases include
fueling torches, blowing down or drying any equipment
such as lab equipment endoscopy or scopes, or any other
purposes. Also prohibited is using the oxygen or medical
air to raise, lower or otherwise operate booms or other
devices…”.
Certain of these prohibitions are controversial, but
the difficulty they cause can be illustrated. Consider
endosurgical areas or central sterile supply. Here, a gas
source is desirable to blow out or dry instruments during
Page 
cleaning and sterilization. Medical Air cannot be used
for this purpose, so the only acceptable alternative has
been to install nitrogen. Aside from the cost of nitrogen,
this use implies releasing quantities of Nitrogen into the
room. Although Nitrogen is itself non-toxic, the release
of too much nitrogen will dilute or displace the oxygen in
the air and can cause asphyxiation. Nitrogen is therefore
not ideal for use in workspace applications such as this,
whereas Instrument Air is very suitable.
Applications for Instrument Air are discussed in NFPA
99 5.1.3.8.2.1: “Instrument Air shall be permitted to be
used for any medical support purpose (e.g. to operate
tools, air driven booms, pendants or similar applications)
and (if appropriate to the procedures) to be used in
laboratories.”
Whereas Medical Air is and Nitrogen may be prohibited
from or undesirable in certain applications, Instrument Air
may be used for any of them.
The simple conclusion is that Instrument Air offers a very
worthwhile design option. It is not for every facility,
because in some it will not offer benefits sufficient to justify
the additional up-front costs. But in our studies to date, we
are surprised how often and at how low a nitrogen usage we
can justify these systems purely on the money saved. Our
experience suggests it is an option every facility (including
facilities already using nitrogen) should at least examine.
Dollars and Cents
A decision to use an Instrument Air system will hinge on
the payback for most facilities. This can be calculated with
reasonable accuracy if a few questions can be answered.
Clearly, a facility which has some history with an existing
nitrogen system will be at an advantage when collecting
many of these answers, but even while a project is only in
planning one can make a satisfactory estimate. Detail 4
is a listing of the data required. Once you have obtained
this data, your BeaconMedaes Sales Consultant has a pre
configured spreadsheet which they can use to help you
calculate the relative costs and system payback.
NFPA Rules for Instrument Air
The requirements for Instrument Air sources are found in
the NFPA 99 under 5.1.3.8, and a few other requirements
are found throughout the document.
Instrument Air and nitrogen under the standard are meant
to be opposite sides of the same coin. Indeed, a simple
guiding principle for working with these systems is that if
in doubt, do what you would have done for Nitrogen, and
you will probably have done the right thing.
The one place where an Instrument Air system is unique
is in the design of the source. Instrument Air source
equipment is unique in it’s form, permitted options and
operating requirements. An overall view of the components
of an Instrument Air source under NFPA 99 are shown in
Detail 5 & 6.

Detail 4
Calculating Comparitive Costs for Nitrogen vs. Instrument Air
Number of cylinders or containers used per Month
A
(if you are evaluating a facility which is not yet in operation, see Detail 12) #
B Cost of each cylinder $
C Cost of each Container (if used) $
D Cost of cylinder rental (demurrage) per month $
E Cost of container rental (demurrage) per month $
Labor rate / Hour for the person changing the cylinders or containers
F
(include benefits and overhead costs if appropriate) $
Estimated time required to complete a standard cylinder or container
G change to ONE side of the manifold, including time to travel to and from the
manifold location. (If your estimate is in minutes, ÷60 for hours) Hours
H Labor cost per change $
Number of cylinders or containers on ONE side of the manifold.
I
(if you are evaluating a facility which is not yet in operation, see Detail X) #
Other known costs (delivery charges, supplier labor charges, manifold
J maintenance or repair, etc.) Ensure these charges are per month.
(if you only know overall charges per year, ÷12 for monthly average) $
K Cost of Power per kWh ¢
L Years for amortization of capital yrs.

Page  Instrument Air

Primary Supply Secondary Supply Quality Control Monitoring

Cylinder Cylinder
Header Header
(manifold)
• Medical Air in Cylinders,
purchased per USP.

• Medical Air in Cylinders,

purchased per USP.
• Reserve Supply in Use
• Reserve Low

• Pressure Low
• Pressure High

• Oil indicators on Filter.

• Dew point Monitoring,
alarm at -30°C (-22°F)

200 psi+ 200 psi+ • Lag Alarm

Compressor(s) Compressor(s) • Oil Separation
• Dryer for -40°
• Filtration to 0.01µ
• Charcoal Odor/Taste Removal

Detail 5 : Instrument Air Source System configurations (Per NFPA 99 )

The particular aspects unique to Instrument Air can be
summarized:
1. Compressor Type: A compressor used for Instrument Air
may be of any type which can produce a pressure greater
than 200 psig. Instrument Air compressors do not have
to be oilless or oilfree (unlike compressors for Medical
Air) but may include lubricated types. This is because
the high pressure required makes lubrication inescapable,
and since Instrument Air is not breathed by the patient or
mixed with oxygen, any oil (should it enter the system) is
less hazardous.
The extraordinary pressure requirement comes from the
need to ensure that the system can emulate the traditional
nitrogen system, which may operate as high as 185 psig.
185 psig is the pressure at which the Instrument Air pipeline
system is designed to operate. Clearly, a compressor with
a top pressure of 175 psig will not be able to achieve this
requirement.
transition to nitrogen was wet air. In applications like
tool drive, the dryness of the air is particularly significant,
as the rapid expansion of air in the tools can produce
adiabatic cooling which can condense moisture where it
would otherwise never appear. Therefore, unlike medical
air, Instrument Air must be dried to a nominal -40° dew
point. This will necessitate desiccant dryers in virtually
all cases.
This combination of filters and dryers is intended to produce
air which will comply with or exceed the specifications
of the Instrument Society of America standard S-7.0.01
Quality Standard for Instrument Air.
4. A secondary or backup system. Unlike other medical gas
systems, failure of an Instrument Air system is unlikely to be
fatal. Nevertheless, the system is critical to any number of
procedures, and if the procedure was suddenly terminated
the patient(s) could be at risk. Thus a backup, just like any
other medical gas system, is required.

2. Specific Filtration and Purification: Although a
lubricated compressor is permitted, oil is not permitted in
the system. Instrument Air sources must have coalescing
filters to remove liquid oil and activated carbon absorbers
to eliminate vapor and gaseous oil. A particulate filter is
also required with a nominal pore size of 0.01µ.
Unlike other systems however, the requirement for that
backup is much less stringent. Uniquely, an Instrument Air
compressor may include a redundant compressor(s) (similar
to that required for Medical air) or it may be seconded by
a bank of cylinders sufficient for one hour’s operation (a
hybrid configuration).

3. Dry to -40°: Recall that a major reason for the historic The allowance for a cylinder secondary offers a much less

Instrument Air Page 

 Instrument Air
Pressure
Relief Valve
Guage
Change
ASME Cylinder Reserve Indicators
Header
5.1.3.4.8 Charcoal
Sight Adsorbers
Glass Regulator
Automatic
Drain
Inlet
Isolation
Manual Valves
Drain
Intake(s) Reserve
Relief Source Filter Outlet
Valve Compressor(s) Isolation
Valve or Check
Receiver
Check Air
Valve Treatment
Aftercooler/ & Control Pressure System
air dryer Monitoring Indicator Pressure
Relief Switch/Sensor
Inlet Isolation Source Valve Demand
Isolation Valve Valve Check
means Compressor
(valve shown)
Source
Valve
Inlet
Isolation Outlet
Valve(s) Isolation
Aftercoolers Valve(s) Legend
Automatic
Ball Valve Trap & Drain
Inlet D.P.
Outlet Isolation Dryer(s)
Valve(s) Check Valve
Isolation Dew Point Demand Pressure
Valve(s) Monitor Check Relief
Pressure Valve
Indicator
Automatic Demand Check
Trap & Drain
Pressure Regulator
Elements of an Instrument Air Source Filter with Change Indicator

Page 
After NFPA 99 2002 Figure A-5.1.3.8
Detail 6 : Instrument Air Source Systems (Per NFPA 99 A.5.1.3.8 )
expensive option for installing smaller systems, and yet
does not greatly reduce the operational safety of the system

Note (3)
Note (3)
System
overall if properly alarmed.

Fault
Where this cylinder secondary is applied, there is a
special allowance in the standard for placing the cylinder

Note (3) Single signal alternate to having each signal on the master. Must activate when any signal within the double lines in that row activates.
header with the Instrument Air compressor itself. This

Header
Low
2ndry
is an exception to the general rule that cylinders are not
permitted to be in the same room with compressors or
pumps. It applies only to the active header used to back
up an Instrument Air compressor. There is no exception for

Header
In Use
2ndry
loose cylinders, even if those are intended for the Instrument
Air system, so these must be stored in an appropriate room
just like all other medical gas cylinders.

Water in
Receiver
Note (1)
Note (1)
High
Although Instrument Air systems are clearly intended to be
compressor driven (otherwise the operating economies will
be lost) it is possible to use a standard medical gas style
manifold to source an Instrument Air system as well.

down Separator
Water in

Note (1)
Note (1)
High
5. The distribution system for Instrument Air will typically

Reserve
be similar to that for Nitrogen, but given it’s many potential

Low

Note (1) Recommended when the compressor is water cooled or a water cooled aftercooler is used.

Detail 7.2 : Instrument Air Source Alarms

uses, it may also be significantly more complex. The actual

Thermal

Note (2)
Note (2)
Shut-
design will of course depend on the facility’s convenience
and preferences. Some options are illustrated in Details

Reserve
in Use
8-10.

Lag in
Use
6. Outlets for Instrument Air must be non interchangeable
with other medical gases. It is not appropriate to use
Header
Low
2ndry

medical air outlets or nitrogen outlets in an Instrument

Air system, even if they are relabelled. NFPA has three

point
High
Dew
requirements for any outlet:

Note (2) Recommended when appropriate for the compressor or pump.

Change-
over

a. Each outlet for a specific gas must be provided with an

outlet not interchangeable with any outlet for another Press or
Low

gas. Vac
Press
Low

b. That when a single gas is operated at multiple pressures,

Press or

the outlet for each pressure be non interchangeable

High

Vac
Press
High

with the outlet for another pressure.

c. That when an outlet is operated at pressures greater

Instrument Air, duplex/multiplex compressor

than 80 psig, that the outlet be of the DISS (threaded)

type, or include a pressure interlock to prevent the
Cylinder x Cylinder x Cylinder Manifold

hose from flying out of the outlet when disengaged.

These requirements taken together mean that the ideal

Instrument Air outlet is the CGA DISS outlet, and this is
Cylinder x Cylinder manifold

the outlet BeaconMedæs recommends for all Instrument

Air terminals, hoses and accessories.
Instrument Air, Hybrid
Source Type
Source

Detail 7.1 : A pipeline label for Instrument Air

Instrument Air Page 

7. Instrument Air has it’s own color coding and labelling
(see Detail 7.1). The color for Instrument Air is a red ground
with white lettering, and the abbreviation is “Instrument
Air”. Standard pressure is 160-185 psig through the
pipeline, and the nonstandard pressure rules will apply for
Instrument Air systems operated at different pressures (see
NFPA 99 5.1.5.15, 5.1.11.1, 5.1.11.2.2, 5.1.11.3.2).
8. Alarm requirements for Instrument Air are similar in
most respects to those for any medical gas system (local,
master and area alarms are all required). However, the
unique configurations permitted for the source do imply
some specific alarm signals (see Detail 7.2).
Design and Installation
Instrument Air systems are designed in the same manner as
any medical gas system (please refer to the BeaconMedæs
Medical Gas Design Guide, Chapter 9 for Medical Support
Gases for detailed instructions).
The design of an Instrument Air system and the selection
of the source requires knowing all the many applications
which it is intended to serve. The first step in the design

Line Pressure
Indicator
Dew Point
Monitor Source Valve D.C. To High
°C Pressure
D.C. Terminals
D.C.

Isolating Valve Line Pressure

Pressure Alarm Switch/Sensor
Indicator Pressure
Relief
Line Pressure Valves,
Regulators

Isolation Valve
Instrument Air
Source
High Pressure

Line Pressure
Indicator

Dew Point
Monitor Source Valve D.C. To Low
°C Pressure
D.C. Terminals
D.C.

Isolating Valve Line Pressure

Pressure Alarm Switch/Sensor
Indicator Pressure
Relief
Line Pressure Valves,
Regulators

Isolation Valve

Low Pressure
Detail 8
A Dual Pressure Arrangement per NFPA 99 5.1.3.4.6
Page  Instrument Air
 Area Alarm
Switch/Sensor
Service Valve
Future Valve D.C.
D.C.

Zone Valve
Remote,
pressure controlled IAir Control Panel
Outlet(s) Pressure controlled
outlet on the
Control Panel

Line Pressure
Indicator
Dew Point
Monitor Source Valve D.C.
°C
D.C.

D.C.

Isolating Valve Line Pressure

Pressure Alarm Switch/Sensor
Indicator Pressure
Relief
Line Pressure Valves,
Regulators
Instrument
Air Isolation Valve
Source

High Pressure
Detail 9
Local Pressure Control

must be to determine what all the applications demand in
terms of pressure and flow, and then to determine the size
of compressor required.
An Instrument Air system will fall into either (and in some
cases both) of two types. Systems for use at high pressures
(e.g. to substitute for Nitrogen) will be designed as would
Nitrogen systems. Systems for exclusively lower pressure
applications (e.g. for labs, central sterile supply, etc.) can
be laid out like any other pressure gas system.
If it is the desire of the facility to supply both high and
Instrument Air
low pressure applications from the same source of supply,
there are some considerations which will affect the design.
NFPA 99 5.1.3.4.6 discourages the construction of what is
termed a distributed pressure system in favor of two distinct
pipeline systems divided at the source and separately
provided with all the necessary controls (see Detail 8).
Nevertheless, the language is sufficiently open, and the
application sufficiently unique that some degree of local
pressure control may be permissible.
If local pressure control is desired, the design of the
system would roughly follow the current practice in the
Page 
 Area Alarm
Switch/Sensor
Service Valve
Future Valve D.C.
D.C.

Secondary Regulator
(Provide one for Device Regulator
each device) (Fixed or
adjustable output)
Zone Valve
Uncontrolled
Outlet(s)

Adapter
To Device(s)
fitting
Outlet
Line Pressure
Indicator
Dew Point
Monitor Source Valve D.C.
°C
D.C.

D.C.

Isolating Valve Line Pressure

Pressure Alarm Switch/Sensor
Indicator Pressure
Relief
Line Pressure Valves,
Regulators
Instrument
Air Isolation Valve
Source

High Pressure
Detail 10
Secondary Pressure Control

O.R. There, the pipeline delivers the maximum pressure
to ensure the best possible flow rate, and Instrument Air
control panels are placed where necessary for control of
the pressure to the tools. Similar local pressure control can
be provided for other devices (see Detail 9).
A third option does exist but is rarely the preferred
implementation. This is illustrated in Detail 10, and simply
involves the piping of the Instrument Air to uniform outlets
operated at the standard 185 psig, and then regulating each
device with it’s own portable regulator fitted to the device
or the permanent outlet.
Page 10
It is also possible to blend the elements of the systems
shown in these three figures to create a hybrid system
appropriate to the facility’s needs.
If a multiple pressure system is contemplated, be sure
to size each of the branches at the appropriate pressure.
Only for the purpose of sizing the source should they be
considered as one system.
In the layout process, outlets are placed first. In O.R.
settings where tool drive is required, a pressure control
box is placed on a convenient wall, and includes one
outlet. A second and occasionally a third outlet are placed
in the closest possible proximity to the O.R. table. These
Instrument Air
are often found on the ceiling columns or booms. These
outlets may be “slaved” from the wall mounted control or
they may employ a scaled down version of the control itself
in the ceiling column or boom. Mounting the controller
on the column or boom is generally superior when flow is
considered, but less desirable from the viewpoint of staff
access and ease of use.
After outlets are placed, the actual piping can be run and
pipe sizing determined. This aspect of design is covered
in detail in Chapter 9 of the BeaconMedæs Design Guide
for Medical Gases.
Change of Use
The economic benefits of Instrument Air can be surprising,
and of course it is the facility which is already struggling
with the costs of a nitrogen system who is likely to see
them most clearly. NFPA does provide for a system to be
converted from one gas to another in a process termed
“Change of Use”.
Change of Use requires that a system originally intended for
one gas and therefore made non-interchangeable for that
gas be converted so that it is equally non-interchangeable
for the new gas. This means changing the source, changing
the outlets, changing the demand checks on alarm
components, relabelling and retesting as if the system
was new. A conversion from nitrogen to Instrument Air
is very feasible under these rules. Since the pipeline itself
need not be disturbed, the cost of such a conversion is
not excessive.
Sizing and Selecting an Instrument Air Source
Any Instrument Air source will consist of a primary source
(usually a compressor) and a reserve source (a second
compressor or a manifold header). Each element is sized
separately and by it’s own rules.
To size the primary compressor, there are two considerations:
first, the compressor must be large enough to drive all the
tools, and second we don’t want to make the compressor
any larger than is absolutely necessary. This is particularly
true since there is a very large diversity in Instrument Air
usage and in fact the average Instrument Air compressor
will not run very much. To express this another way, when
the Instrument Air is needed, there must be enough of it,
but it is only typically needed in short bursts, so the system
may sit idle for long periods.
The picture can be further complicated if the Instrument Air
is being used for purposes in addition to driving surgical
tools. Naturally, some of the other applications may
place more steady demand on the system and change the
diversity required.
Instrument Air
The first consideration in sizing is to ensure that the tools
which are likely to be in simultaneous use are covered.
These tools can be very demanding, with typical usages
ranging from 225-425 lpm (8-15 scfm). At least this
quantity of air must be available, so this is the minimum
size for a system.
More than one location will involve some degree of
simultaneous use, and the calculation we recommend is
that used by the HTM 2022 standard from the U.K., which
allows for one tool at 100% and all remaining tools at 25%.
The formula used is :
350 + ((n-1) x 87.5)
Where n is the number of locations using the system.
Where 350 lpm is taken as the base load for a tool, and
“n” is the number of locations piped with Instrument Air
or the number of tools.
If other applications are intended to use Instrument
Air, they must be added to the tool demand based on a
knowledge of the actual demand from that application.
Some examples might include: operating pneumatic brakes
for booms, which use negligible amounts of air and can
be ignored as a capacity requirement; operating tools in
the morgue, which might be treated like another tool-using
location; operating a pneumatic O.R. table, which would
have to be assessed based on a knowledge of the table
itself; general lab uses, which might easily be greater than
the use of air for tools when totalled.
The sizing of the reserve is identical if a duplex compressor
is used as the source configuration. If the source
configuration is a compressor with a cylinder header as
reserve (a hybrid configuration), then the secondary must
contain one hour’s supply. This is most easily assessed
by taking the total demand calculated for the primary
source and multiplying it by 60 (minutes to hours), then
dividing by 6,200 l (220 scfm) to determine the number of
cylinders required in the secondary (Detail 12 allows you
to determine this with minimal calculations).
In the rare event that a manifold source will be used, this
will be sized using a simple calculation of one cylinder
for each ordinary O.R., and two for each O.R. intended
for orthopedic or neurological surgery. Both sides of the
manifold will be identically sized. If other applications
are also going to be served form the manifold, they must
be assessed individually.
The selection of the Instrument Air source may be made
from Detail 13, which also will link you to the necessary
information for system dimensions.
Conclusions and Cautions
We believe that ultimately Instrument Air, especially when
Page 11
 Source Ranges Instrument Air
(Locations scale reflects Tool use only, HTM 2022 Sizing Method)

(3) 7.5 Hp. (3) 10 Hp.

Quadruplex

Triplex Note: Larger I. Air

systems are possible.
Duplex Please contact
10 Hp. (2) 10 Hp.* BeaconMedæs for
information.
7.5 Hp. (2) 7.5 Hp.*

}
Compressor(s)
5 7 11 16 Secondary Cylinder Hybrid Systems
Counts
14x14 7-14
13x13 6-13 Source Type Legend
12x12 6-12
11x11 5-11
10x10 5-10
9x9 4-9
8x8 4-8
Cylinder
7x7 3-7 Manifolds
6x6 3-6
5x5 2-5
4x4 2-4
3x3 1-3
2x2 1-2

1 10 20
Number of Locations piped with Instrument Air
Notes: The ranges given for manifolds reflect a low (dark blue) and a high (white)
estimate. The low estimate applies only if all locations are of the general O.R. type,
the high estimate applies if all are of the specialty O.R. type. Factor your selection
based on the proportion of each in the project.
* Hybrid configurations marked with a “*” are systems with two compressors of this
size as the primary source. They are not duplex systems in the usual meaning of one
compressor in service, one on standby, but have two compressors available in the
primary role with cylinders as the secondary.

Detail 12 : Instrument Air Source Selector

compared to Nitrogen, is a superior choice for any facility
which needs high pressure gas for any reason. In the long
run, the benefits are so compelling that we can anticipate
nitrogen systems disappearing from the scene, entirely
replaced by Instrument Air.
However, that is some time in the future, and any facility
built since at least the 1970’s probably has a nitrogen
system already in place. Although the economics of
Instrument Air are compelling, they are far more complex
when a legacy system must also be considered.
Instrument Air systems are more costly initially, but the
gas is far less expensive per liter. This means that there
is a payback for virtually any Instrument Air installation,
whether new or a change of use. The question is the time
Page 12
frame for that payback. Naturally, the general rule will be
the more gas used, the faster the payback. Small facilities
using very little gas may find the payback too far in the
future to justify the initial outlay, large facilities with heavy
usage may find the savings grand enough to justify even
a complicated change of use program. The only way to
know is to do the math.
We highly recommend that every medical gas design
engineer add Instrument Air to their repertoire, and in
future evaluate every facility as a potential candidate. They
will find in most cases Instrument Air is a money saver for
their client.
Facilities who have to work to keep their nitrogen
Instrument Air
systems from going empty should also look closely at the
possibilities of performing a change of use conversion.
They are likely to find the economics more favorable than
they expected.
That middle range of facilities whose nitrogen usage is
a nuisance but not high enough to justify the costs of
conversion will be the ones who will have to refuse change
of use. Should they ever be fortunate enough to renovate
their O.R. or build new, they will certainly find Instrument
Air very attractive, but they may be best advised to leave
well enough alone in the interim.
There are other possibilities for reducing the cost and labor
involved with nitrogen which may be a half-way solution
for such facilities. These involve conversion from cylinder
(gaseous) sources to container (liquid) sources. While
nitrogen will always be more expensive than compressed
air, the reduction in cost can be significant, and the
reduction in labor can be greater yet. More details on these
systems can be obtained in the BeaconMedaes Applications
Guide to Cryogenic Liquid Manifolds available through
your BeaconMedaes representative.

Detail 13
System Selection Table, Instrument Air Compressors
Capacity NFPA Complete System
@ 200 psig Envelope Dimensions (inches)
Cyl. Information
SCFM LPM Format HP Count Width Height Depth Sheet Page
16.5 467 Duplex1 7.5 NA 103.5 84.5 67 SSB-120-10 15
24 679 Duplex1 10 NA 103.5 84.5 67 SSB-120-10 15
33 934 Triplex1 7.5 NA 138 84.5 67 SSB-120-11 17
48 1,359 Triplex1 10 NA 138 84.5 67 SSB-120-11 17
49.5 1,401 Quadruplex1 7.5 NA 172.5 84.5 67 SSB-120-12 19
72 2,038 Quadruplex1 10 NA 172.5 84.5 67 SSB-120-12 19
Hybrid Systems
16.5 467 Simplex2 7.5 5 89.5 85 67 SSB-120-10 21
24 679 Simplex2 10 7 89.5 85 67 SSB-120-10 21
33 934 Duplex2 7.5
Call for information
48 1,359 Duplex2 10

Notes
1. Capacites are shown as NFPA capacities with one compressor running and one in standby. Capacity shown is net
system capacity, not simple compressor capacity (systems losses are already deducted).
2. Capacites are shown as NFPA capacities with compressor(s) running and cylinder header in standby. Capacity
shown is net system capacity, not simple compressor(s) capacity (systems losses are already deducted).

Instrument Air Page 13


This product has been designed to meet U.S. NFPA 99, latest edition.
Modifications made to meet current CSA Standards may result in changes to
the product's weight and physical dimensions. Please contact BeaconMedæs at
(704) 588-0854 or (704) 588-4949 (fax) for further information.
Instrument Air Duplex Single Point Connection (SPC) Base Mount Systems
(7½ - 10 HP)
SPECIFICATION
SPC (Single Point Connection) System Design
The instrument air system shall be of a single point connection
base mounted design consisting of two compressor modules
with dryers, and a single control module with control panel,
air receiver, filtration system and oil/water condensate
separator. Each module has a maximum base width of 34.50"
(88 cm), and be fully compliant with the latest edition of
NFPA 99. The modules shall be assembled as one unit with
single point connections for air discharge, electrical and
condensate drain.
Compressor/Dryer Module (Compressor, Drive, Motor,
Piping, Dryer)
The compressor shall be a high pressure "oil-lubricated"
continuous duty rated type. The design shall be two staged,
air-cooled, reciprocating type with corrosion resistant reed
type valves with stainless steel reeds. Both oil scrapper ring
and piston rings shall be made from long lasting special cast
iron and designed for continuous duty operation. The
crankshaft shall be constructed of forged steel and fully
supported on both ends by heavy duty ball bearings and seals.
The crankcase shall be constructed of gray cast iron.
Maximum heat dissipation shall be achieved through cast iron
cylinders with external cooling vanes. Cylinder sleeves are not
required. Both low and high pressure pistons are made from
cast aluminum with chrome-moly piston pins. Second stage
cylinder head shall be equipped with a wired shutdown switch
for high discharge air temperature. The connecting rod shall
be of a one-piece design. The compressor shall be v-belt
driven through a combination flywheel/sheave and steel motor
sheave with tapered bushing and protected by an OSHA
approved totally enclosed belt guard. A sliding motor
mounting base that is fully adjustable through twin adjusting
screws shall achieve belt tensioning. The motor shall be a
NEMA rated, open drip proof, 1800 RPM, with 1.15 service
factor suitable for 208 or 230/460V electrical service. Each
compressor shall have its own inlet air filter mounted on the
first stage compressor heads. Discharge air from the first
stage compressor cylinder passes through an air-cooled
intercooler prior to entering the second stage. The second
stage discharge air then passes through an air-cooled
aftercooler designed for a maximum approach temperature of
12° F complete with moisture separator and zero loss
automatic drain valve prior to entering the dryer. The
compressor discharge line shall include a flex connector,
safety relief valve, isolation valve, and check valve. The
discharge air piping shall be of ASTM B-819 copper tubing,
brass, and/or stainless steel. The discharge flex connector shall
be braided 304 stainless steel, brass, or bronze. Each
compressor has its own dedicated dryer. Each dryer is
individually sized for peak calculated demand and capable of
producing a -40° F (-40° C) pressure dew point. Dryer purge
only occurs when it’s respective compressor is running.
Upstream of the dryer will be a separator with a zero loss
drain valve followed by a 0.01 micron coalescing filter. Both
filters shall have element change indicators.
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854
DUPLEX 7.5-10
BASE MOUNT
SSB-120-10
Page 1 of 2
10/01/06
Isolation System
Each compressor and motor assembly shall be fully isolated
from the main compressor module base by means of a four
point, heavy duty, spring isolation system for a minimum of
95% isolation efficiency. Where required by local or state
regulation, optional seismically restrained isolators can be
provided at an additional cost. Each main compressor module
base frame shall not exceed 34.50" in width.
Control Module with Air Receiver/Filter/Regulator
System
The control module shall include a NEMA 12, U.L. labeled
control system, duplexed final line filters, regulators, oil
indicators, and a condensate oil/water separator and dew point
monitor. All of the above shall be factory piped and wired in
accordance with NFPA 99 and include valving to allow
complete air receiver bypass and an air sampling port. The
vertical air receiver shall be ASME Coded, National Board
Certified, galvanized, rated for a minimum 250 PSIG design
pressure and includes a liquid level gauge glass, safety relief
valve, manual drain valve, and automatic solenoid drain valve.
Control System
The control system shall have an HMI touch screen control,
automatic lead/lag sequencing with circuit breaker disconnects
for each motor with external operators, full voltage motor
starters, overload protection, 24V control circuit and hand-off-
auto selector switch for each compressor. Automatic
alternation of both compressors based on first-on/first-off
principle with provisions for simultaneous operation if
required. Automatic activation of reserve unit, if required, will
activate an audible alarm as well as a visual alarm on the
HMI. The HMI displays service due, run hours for each
compressor, system status, operating pressure, dew point and
high discharge air temperature shutdown. A complete alarm
and service history is available on the HMI.
Dew Point Transmitter
The control module shall incorporate a dew point transmitter
that is mounted, pre-piped, wired to the control panel and
displayed on the HMI touch screen. The transmitter probe
shall be 316L SS with sintered stainless steel filter and thin
film polymer sensor. The system accuracy shall be ± 2° C.
Dew point alarm shall be factory set at -22° F (-30° C) per
NFPA 99 with remote alarm contacts in the control panel.
Statement of Warranty
BeaconMedæs warrants all Instrument Air Systems, to be free
of defects in material and workmanship under normal use for
a period not to exceed thirty (30) months from date of
shipment, or twenty four (24) months from date of start-up.
Fax: (704) 588-4949 Page 15
 This product has been designed to meet U.S. NFPA 99, latest edition.
SSB-120-10
Modifications made to meet current CSA Standards may result in changes to Page 2 of 2
the product's weight and physical dimensions. Please contact BeaconMedæs at 10/01/06
(704) 588-0854 or (704) 588-4949 (fax) for further information.

Instrument Air System Specifications1

Complete System Capacity2 System FLA

System3 Receiver4 Noise5
System HP
BTU/HR (Gallons) Level
Model No. 200 psig 208V 230V 460V
HPA-7D-D200 7½ 16.5 17,062 200* 76 46 41 20
HPA-10D-D200 10 24 23,014 200* 79 60 52 26

Notes: 1 Normal operating conditions at a maximum ambient of 105° F. Consult factory for higher ambient conditions.
2 All capacities are shown as NFPA system capacities (reserve compressor on standby) and are shown in Inlet Cubic
Feet per Minute (ICFM). System losses subtracted from pump capacity.
3 All system BTU/HR is shown with reserve compressor on standby.
4 * Indicates standard receiver
5 All noise levels are shown in dB(A) and reflect one pump running.

Page 16
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854 Fax: (704) 588-4949

This product has been designed to meet U.S. NFPA 99, latest edition.
Modifications made to meet current CSA Standards may result in changes to
the product's weight and physical dimensions. Please contact BeaconMedæs at
(704) 588-0854 or (704) 588-4949 (fax) for further information.
Instrument Air Triplex Single Point Connection (SPC) Base Mount Systems
(7½ - 10 HP)
SPECIFICATION
SPC (Single Point Connection) System Design
The instrument air system shall be of a single point connection
base mounted design consisting of three compressor modules
with dryers, and a single control module with control panel,
air receiver, filtration system and oil/water condensate
separator. Each module has a maximum base width of 34.50"
(88 cm), and be fully compliant with the latest edition of
NFPA 99. The modules shall be assembled as one unit with
single point connections for air discharge, electrical and
condensate drain.
Compressor/Dryer Module (Compressor, Drive, Motor,
Piping, Dryer)
The compressor shall be a high pressure "oil-lubricated"
continuous duty rated type. The design shall be two staged,
air-cooled, reciprocating type with corrosion resistant reed
type valves with stainless steel reeds. Both oil scrapper ring
and piston rings shall be made from long lasting special cast
iron and designed for continuous duty operation. The
crankshaft shall be constructed of forged steel and fully
supported on both ends by heavy duty ball bearings and seals.
The crankcase shall be constructed of gray cast iron.
Maximum heat dissipation shall be achieved through cast iron
cylinders with external cooling vanes. Cylinder sleeves are not
required. Both low and high pressure pistons are made from
cast aluminum with chrome-moly piston pins. Second stage
cylinder head shall be equipped with a wired shutdown switch
for high discharge air temperature. The connecting rod shall
be of a one-piece design. The compressor shall be v-belt
driven through a combination flywheel/sheave and steel motor
sheave with tapered bushing and protected by an OSHA
approved totally enclosed belt guard. A sliding motor
mounting base that is fully adjustable through twin adjusting
screws shall achieve belt tensioning. The motor shall be a
NEMA rated, open drip proof, 1800 RPM, with 1.15 service
factor suitable for 208 or 230/460V electrical service. Each
compressor shall have its own inlet air filter mounted on the
first stage compressor heads. Discharge air from the first
stage compressor cylinder passes through an air-cooled
intercooler prior to entering the second stage. The second
stage discharge air then passes through an air-cooled
aftercooler designed for a maximum approach temperature of
12° F complete with moisture separator and zero loss
automatic drain valve prior to entering the dryer. The
compressor discharge line shall include a flex connector,
safety relief valve, isolation valve, and check valve. The
discharge air piping shall be of ASTM B-819 copper tubing,
brass, and/or stainless steel. The discharge flex connector shall
be braided 304 stainless steel, brass, or bronze. Each
compressor has its own dedicated dryer. Each dryer is
individually sized for peak calculated demand and capable of
producing a -40° F (-40° C) pressure dew point. Dryer purge
only occurs when it’s respective compressor is running.
Upstream of the dryer will be a separator with a zero loss
drain valve followed by a 0.01 micron coalescing filter. Both
filters shall have element change indicators.
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854
TRIPLEX 7.5-10
BASE MOUNT
SSB-120-11
Page 1 of 2
10/01/06
Isolation System
Each compressor and motor assembly shall be fully isolated
from the main compressor module base by means of a four
point, heavy duty, spring isolation system for a minimum of
95% isolation efficiency. Where required by local or state
regulation, optional seismically restrained isolators can be
provided at an additional cost. Each main compressor module
base frame shall not exceed 34.50" in width.
Control Module with Air Receiver/Filter/Regulator
System
The control module shall include a NEMA 12, U.L. labeled
control system, duplexed final line filters, regulators, oil
indicators, and a condensate oil/water separator and dew point
monitor. All of the above shall be factory piped and wired in
accordance with NFPA 99 and include valving to allow
complete air receiver bypass and an air sampling port. The
vertical air receiver shall be ASME Coded, National Board
Certified, galvanized, rated for a minimum 250 PSIG design
pressure and includes a liquid level gauge glass, safety relief
valve, manual drain valve, and automatic solenoid drain valve.
Control System
The control system shall have an HMI touch screen control,
automatic lead/lag sequencing with circuit breaker disconnects
for each motor with external operators, full voltage motor
starters, overload protection, 24V control circuit and hand-off-
auto selector switch for each compressor. Automatic
alternation of all compressors based on first-on/first-off
principle with provisions for simultaneous operation if
required. Automatic activation of reserve unit, if required, will
activate an audible alarm as well as a visual alarm on the
HMI. The HMI displays service due, run hours for each
compressor, system status, operating pressure, dew point and
high discharge air temperature shutdown. A complete alarm
and service history is available on the HMI.
Dew Point Transmitter
The control module shall incorporate a dew point transmitter
that is mounted, pre-piped, wired to the control panel and
displayed on the HMI touch screen. The transmitter probe
shall be 316L SS with sintered stainless steel filter and thin
film polymer sensor. The system accuracy shall be ± 2° C.
Dew point alarm shall be factory set at -22° F (-30° C) per
NFPA 99 with remote alarm contacts in the control panel.
Statement of Warranty
BeaconMedæs warrants all Instrument Air Systems, to be free
of defects in material and workmanship under normal use for
a period not to exceed thirty (30) months from date of
shipment, or twenty four (24) months from date of start-up.
Fax: (704) 588-4949
Page 17
 This product has been designed to meet U.S. NFPA 99, latest edition.
SSB-120-11
Modifications made to meet current CSA Standards may result in changes to Page 2 of 2
the product's weight and physical dimensions. Please contact BeaconMedæs at 10/01/06
(704) 588-0854 or (704) 588-4949 (fax) for further information.

Instrument Air System Specifications1

Complete System Capacity2 System FLA

System3 Receiver4 Noise5
System HP
BTU/HR (Gallons) Level
Model No. 200 psig 208V 230V 460V
HPA-7T-D200 7½ 33 34,124 200* 76 69 60 30
HPA-10T-D200 10 48 46,028 200* 79 90 78 39

Notes: 1 Normal operating conditions at a maximum ambient of 105° F. Consult factory for higher ambient conditions.
2 All capacities are shown as NFPA system capacities (reserve compressor on standby) and are shown in Inlet Cubic
Feet per Minute (ICFM). System losses subtracted from pump capacity.
3 All system BTU/HR is shown with reserve compressor on standby.
4 * Indicates standard receiver
5 All noise levels are shown in dB(A) and reflect one pump running.

Page 18
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854 Fax: (704) 588-4949

This product has been designed to meet U.S. NFPA 99, latest edition.
Modifications made to meet current CSA Standards may result in changes to
the product's weight and physical dimensions. Please contact BeaconMedæs at
(704) 588-0854 or (704) 588-4949 (fax) for further information.
Instrument Air Quadruplex Single Point Connection (SPC) Base Mount Systems
(7½ - 10 HP)
SPECIFICATION
SPC (Single Point Connection) System Design
The instrument air system shall be of a single point connection
base mounted design consisting of four compressor modules
with dryers, and a single control module with control panel,
air receiver, filtration system and oil/water condensate
separator. Each module has a maximum base width of 34.50"
(88 cm), and be fully compliant with the latest edition of
NFPA 99. The modules shall be assembled as one unit with
single point connections for air discharge, electrical and
condensate drain.
Compressor/Dryer Module (Compressor, Drive, Motor,
Piping, Dryer)
The compressor shall be a high pressure "oil-lubricated"
continuous duty rated type. The design shall be two staged,
air-cooled, reciprocating type with corrosion resistant reed
type valves with stainless steel reeds. Both oil scrapper ring
and piston rings shall be made from long lasting special cast
iron and designed for continuous duty operation. The
crankshaft shall be constructed of forged steel and fully
supported on both ends by heavy duty ball bearings and seals.
The crankcase shall be constructed of gray cast iron.
Maximum heat dissipation shall be achieved through cast iron
cylinders with external cooling vanes. Cylinder sleeves are not
required. Both low and high pressure pistons are made from
cast aluminum with chrome-moly piston pins. Second stage
cylinder head shall be equipped with a wired shutdown switch
for high discharge air temperature. The connecting rod shall
be of a one-piece design. The compressor shall be v-belt
driven through a combination flywheel/sheave and steel motor
sheave with tapered bushing and protected by an OSHA
approved totally enclosed belt guard. A sliding motor
mounting base that is fully adjustable through twin adjusting
screws shall achieve belt tensioning. The motor shall be a
NEMA rated, open drip proof, 1800 RPM, with 1.15 service
factor suitable for 208 or 230/460V electrical service. Each
compressor shall have its own inlet air filter mounted on the
first stage compressor heads. Discharge air from the first
stage compressor cylinder passes through an air-cooled
intercooler prior to entering the second stage. The second
stage discharge air then passes through an air-cooled
aftercooler designed for a maximum approach temperature of
12° F complete with moisture separator and zero loss
automatic drain valve prior to entering the dryer. The
compressor discharge line shall include a flex connector,
safety relief valve, isolation valve, and check valve. The
discharge air piping shall be of ASTM B-819 copper tubing,
brass, and/or stainless steel. The discharge flex connector shall
be braided 304 stainless steel, brass, or bronze. Each
compressor has its own dedicated dryer. Each dryer is
individually sized for peak calculated demand and capable of
producing a -40° F (-40° C) pressure dew point. Dryer purge
only occurs when it’s respective compressor is running.
Upstream of the dryer will be a separator with a zero loss
drain valve followed by a 0.01 micron coalescing filter. Both
filters shall have element change indicators.
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854
BASE MOUNT
SSB-120-12
QUAD 7.5-10
Page 1 of 2
10/01/06
Isolation System
Each compressor and motor assembly shall be fully isolated
from the main compressor module base by means of a four
point, heavy duty, spring isolation system for a minimum of
95% isolation efficiency. Where required by local or state
regulation, optional seismically restrained isolators can be
provided at an additional cost. Each main compressor module
base frame shall not exceed 34.50" in width.
Control Module with Air Receiver/Filter/Regulator
System
The control module shall include a NEMA 12, U.L. labeled
control system, duplexed final line filters, regulators, oil
indicators, and a condensate oil/water separator and dew point
monitor. All of the above shall be factory piped and wired in
accordance with NFPA 99 and include valving to allow
complete air receiver bypass and an air sampling port. The
vertical air receiver shall be ASME Coded, National Board
Certified, galvanized, rated for a minimum 250 PSIG design
pressure and includes a liquid level gauge glass, safety relief
valve, manual drain valve, and automatic solenoid drain valve.
Control System
The control system shall have an HMI touch screen control,
automatic lead/lag sequencing with circuit breaker disconnects
for each motor with external operators, full voltage motor
starters, overload protection, 24V control circuit and hand-off-
auto selector switch for each compressor. Automatic
alternation of all compressors based on first-on/first-off
principle with provisions for simultaneous operation if
required. Automatic activation of reserve unit, if required, will
activate an audible alarms as well as a visual alarm on the
HMI. The HMI displays service due, run hours for each
compressor, system status, operating pressure, dew point and
high discharge air temperature shutdown. A complete alarm
and service history is available on the HMI.
Dew Point Transmitter
The control module shall incorporate a dew point transmitter
that is mounted, pre-piped, wired to the control panel and
displayed on the HMI touch screen. The transmitter probe
shall be 316L SS with sintered stainless steel filter and thin
film polymer sensor. The system accuracy shall be ± 2° C.
Dew point alarm shall be factory set at -22° F (-30° C) per
NFPA 99 with remote alarm contacts in the control panel.
Statement of Warranty
BeaconMedæs warrants all Instrument Air Systems, to be free
of defects in material and workmanship under normal use for
a period not to exceed thirty (30) months from date of
shipment, or twenty four (24) months from date of start-up.
Fax: (704) 588-4949
Page 19
 This product has been designed to meet U.S. NFPA 99, latest edition.
SSB-120-12
Modifications made to meet current CSA Standards may result in changes to Page 2 of 2
the product's weight and physical dimensions. Please contact BeaconMedæs at 10/01/06
(704) 588-0854 or (704) 588-4949 (fax) for further information.

Instrument Air System Specifications1

Complete System Capacity2 System FLA

System3 Receiver4 Noise5
System HP
BTU/HR (Gallons) Level
Model No. 200 psig 208V 230V 460V
HPA-7Q-D200 7½ 49.5 51,186 200* 76 92 80 40
HPA-10Q-D200 10 72 69,042 200* 79 119 104 52

Notes: 1 Normal operating conditions at a maximum ambient of 105° F. Consult factory for higher ambient conditions.
2 All capacities are shown as NFPA system capacities (reserve compressor on standby) and are shown in Inlet Cubic
Feet per Minute (ICFM). System losses subtracted from pump capacity.
3 All system BTU/HR is shown with reserve compressor on standby.
4 * Indicates standard receiver
5 All noise levels are shown in dB(A) and reflect one pump running.

Page 20
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854 Fax: (704) 588-4949

This product has been designed to meet U.S. NFPA 99, latest edition.
Modifications made to meet current CSA Standards may result in changes to
the product's weight and physical dimensions. Please contact BeaconMedæs at
(704) 588-0854 or (704) 588-4949 (fax) for further information.
Instrument Air Simplex Single Point Connection (SPC) Base Mount Systems
with Cylinder Air Back-up Header (7½ - 10 HP)
SPECIFICATION
SPC (Single Point Connection) System Design
The instrument air system shall be of a single point connection
base mounted design consisting of one compressor module
with dryer, and a single control module with control panel, air
receiver, filtration system, oil/water condensate separator and
backup cylinder header for cylinder air. Each module has a
maximum base width of 34.50" (88 cm), and be fully
compliant with the latest edition of NFPA 99. The modules
shall be assembled as one unit with single point connections
for air discharge, electrical and condensate drain.
Compressor/Dryer Module (Compressor, Drive, Motor,
Piping, Dryer)
The compressor shall be a high pressure "oil-lubricated"
continuous duty rated type. The design shall be two staged,
air-cooled, reciprocating type with corrosion resistant reed
type valves with stainless steel reeds. Both oil scraper ring and
piston rings shall be made from long lasting special cast iron
and designed for continuous duty operation. The crankshaft
shall be constructed of forged steel and fully supported on
both ends by heavy duty ball bearings and seals. The
crankcase shall be constructed of gray cast iron. Maximum
heat dissipation shall be achieved through cast iron cylinders
with external cooling vanes. Cylinder sleeves are not required.
Both low and high pressure pistons are made from cast
aluminum with chrome-moly piston pins. Second stage
cylinder head shall be equipped with a wired shutdown switch
for high discharge air temperature. The connecting rod shall
be of a one-piece design. The compressor shall be v-belt
driven through a combination flywheel/sheave and steel motor
sheave with tapered bushing and protected by an OSHA
approved totally enclosed belt guard. A sliding motor
mounting base that is fully adjustable through twin adjusting
screws shall achieve belt tensioning. The motor shall be a
NEMA rated, open drip proof, 1800 RPM, with 1.15 service
factor suitable for 208 or 230/460V electrical service. Each
compressor shall have its own inlet air filter mounted on the
first stage compressor heads. Discharge air from the first
stage compressor cylinder passes through an air-cooled
intercooler prior to entering the second stage. The second
stage discharge air then passes through an air-cooled
aftercooler designed for a maximum approach temperature of
12° F complete with moisture separator and zero loss
automatic drain valve prior to entering the dryer. The
compressor discharge line shall include a flex connector,
safety relief valve, isolation valve, and check valve. The
discharge air piping shall be of ASTM B-819 copper tubing,
brass, and/or stainless steel. The discharge flex connector shall
be braided 304 stainless steel, brass, or bronze. The dryer is
individually sized for peak calculated demand and capable of
producing a -40° F (-40° C) pressure dew point. Dryer purge
only occurs when the compressor is running. Upstream of the
dryer will be a separator with a zero loss drain valve followed
by a 0.01 micron coalescing filter. Both filters shall have
element change indicators.
Isolation System
The compressor and motor assembly shall be fully isolated
from the main compressor module base by means of a four
point, heavy duty, spring isolation system for a minimum of
95% isolation efficiency. Where required by local or state
regulation, optional seismically restrained isolators can be
provided at an additional cost.
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854
SIMLEX 7.5-10
BASE MOUNT
SSB-120-13
Page 1 of 2
10/01/06
Control Module with Air Receiver/Filter/Regulator
System
The control module shall include a NEMA 12, U.L. labeled
control system, duplexed final line filters, regulators, oil
indicators, condensate oil/water separator, dew point monitor
and an air sample port, backup cylinder header and cylinder
restraint system. All of the above shall be factory piped and
wired in accordance with NFPA 99. The vertical air receiver
shall be ASME Coded, National Board Certified, galvanized,
rated for a minimum 250 PSIG design pressure and includes a
liquid level gauge glass, safety relief valve, manual drain
valve, and automatic solenoid drain valve.
Backup Air Cylinder Header
A high-pressure header shall be provided to accommodate
multiple air cylinders with staggered cylinder connections on
5" centers. The header shall be designed for inlet pressures up
to 3000 psig and shall be provided with a flexible pigtail with
check valve for each cylinder connection. Pigtail connections
shall be CGAV-1 #346 cylinder connections. A pressure
regulator (field adjustable; 40 to 300 psig) shall be provided
on the backup header to regulate the cylinder pressure. The
regulator shall utilize high-pressure brass unions at the inlet
and outlet connections for attachment to the header assembly
and supply line. The simplex header shall be provided with a
backup low pressure switch and a low flow adapter. The
header shall be provided with a high-pressure master shut-off
valve to isolate the header from the system, during service and
repairs, without affecting the remainder of the system. The
header shall be factory piped to the inlet side of the duplexed
final line filters.
Control System
The duplex mounted and wired control system shall be NEMA
12 and U.L. labeled. The control system shall have an HMI
touch screen control, automatic lead/lag sequencing with
circuit breaker disconnects for each motor with external
operators, full voltage motor starters, overload protection, 24V
control circuit and hand-off-auto selector switch for each
compressor. Automatic alternation of both compressors based
on first-on/first-off principle with provisions for simultaneous
operation if required. Automatic activation of reserve unit, if
required, will activate an audible alarm as well as a visual
alarm on the HMI. The HMI displays service due, run hours,
system status, operating pressure, dew point and high
discharge air temperature shutdown. A complete alarm and
service history is available on the HMI.
Dew Point Transmitter
The control module shall incorporate a dew point transmitter
that is mounted, pre-piped, wired to the control panel and
displayed on the HMI touch screen. The transmitter probe
shall be 316L SS with sintered stainless steel filter and thin
film polymer sensor. The system accuracy shall be ± 2° C.
Dew point alarm shall be factory set at -22° F (-30° C) per
NFPA 99 with remote alarm contacts in the control panel.
Statement of Warranty
BeaconMedæs warrants all Instrument Air Systems, to be free
of defects in material and workmanship under normal use for
a period not to exceed thirty (30) months from date of
shipment, or twenty four (24) months from date of start-up.
Fax: (704) 588-4949
 This product has been designed to meet U.S. NFPA 99, latest edition.
SSB-120-13
Modifications made to meet current CSA Standards may result in changes to Page 2 of 2
the product's weight and physical dimensions. Please contact BeaconMedæs at 10/01/06
(704) 588-0854 or (704) 588-4949 (fax) for further information.

Instrument Air System Specifications1

System
Complete System FLA
Capacity2 System3 Receiver4 Noise No. of
System HP
BTU/HR (Gallons) Level5 Cylinders6
Model No. 200 psig 208V 230V 460V
HPA-7S-D200 7½ 16.5 17,062 200* 76 5 23 20 10
HPA-10S-D200 10 24 23,014 200* 79 7 30 26 13
Notes: 1 Normal operating conditions at a maximum ambient of 105° F. Consult factory for higher ambient conditions.
2 All capacities are shown as NFPA system capacities (reserve compressor on standby) and are shown in Inlet Cubic
Feet per Minute (ICFM). System losses subtracted from pump capacity.
3 All system BTU/HR is shown with reserve compressor on standby.
4 * Indicates standard receiver
5 All noise levels are shown in dB(A) and reflect one pump running.
6 Number of air cylinders for 1-hour of backup. All cylinders are supplied by others.

Page 22
BeaconMedæs Š P. O. Box 7064 Charlotte, N. C. 28241 Š Phone: (704) 588-0854 Fax: (704) 588-4949
 SERIES B DISS
WALL OUTLET
SSB-840-03
Page 1 of 2
2/01/2006

Series B Recessed Medical Gas Wall Outlet

DISS Key Style
SPECIFICATION
DISS Medical Gas Wall Outlet identification shall be affixed to the inlet tube and the face of
The DISS Medical Gas wall outlets shall be gas specific for the mounting plate. A secondary valve shall be installed in
the services indicated and accept only corresponding DISS the outlet block of the rough-in assembly for both pressure
nuts and nipples. The outlets shall be UL listed, CSA certified, testing and preventing gas flow (except vacuum and WAGD)
and be fully compliant with the latest edition of NFPA 99. All when the latch-valve assembly is removed for service. A 3/8"
outlets shall be 100% tested for flow, leaks and connector high metal flange around the outlet opening shall provide a
attachment. The outlets shall be cleaned for oxygen service plaster barrier. A temporary cover shall be provided to keep
prior to shipping. The outlets shall be made in the U.S.A. A debris out of the outlet during installation. The rough-in
die cast, light gray, epoxy powder coated trim plate can be assembly shall contain a double seal to prevent gas leakage
provided to trim each wall outlet and to fill the space between between the rough-in and latch-valve assemblies after the wall
adjacent outlets. The trim plate shall allow latch valves to be is finished. A single o-ring seal shall not be acceptable.
individually removed for servicing. Latch Valve Assembly
Outlet Design The latch-valve assembly shall include an o-ring seal primary
A complete medical gas outlet shall consist of a gas-specific valve, be gas specific for the labeled service, and accept only
rough-in assembly for installation before the wall is finished corresponding hose and apparatus with DISS nut and nipple
and a matching gas-specific latch-valve assembly and cover adapters. The latch-valve assembly shall be indexed to the
plate for installation after the wall is finished. corresponding rough-in assembly to avoid accidental
Rough-in Assembly cross-connection and shall telescope up to 3/4" to allow for
The rough-in assembly shall be of modular design and include variation in finished wall thickness from 1/2" up to 1-1/4". A
a gas-specific 16-gauge steel mounting plate designed to metal cover plate insert with permanent, color-coded marking
permit on-site ganging of multiple outlets, in any order, on 5" of service identification shall be included as part of the
centerline spacing. A machined brass outlet block shall be latch-valve assembly.
permanently attached to the mounting bracket to permit the
1/2" OD (3/8" nominal),type-K copper inlet tube to swivel
360° for attachment to the piping system. Gas service
Item Concealed Wall Outlet
Gas Service Color Code Complete Assembly Rough-in Assembly Latch-Valve Assembly
Series B O2 White F 6-121100-00 F 6-233110-00 F 6-230910-00
DISS N2O Blue F 6-121101-00 F 6-233111-00 F 6-230911-00
(U.S.) AIR Yellow F 6-121102-00 F 6-233112-00 F 6-230912-00
VAC White F 6-121103-00 F 6-233113-00 F 6-230913-00
N2 Black F 6-121104-00 F 6-233114-00 F 6-230914-00
Instrument Air Red F 6-121108-00 F 6-233118-00 F 6-230916-00
WAGD Purple F 6-121109-00 F 6-233119-00 F 6-230919-00
CO2 Gray F 6-121110-00 F 6-233120-00 F 6-230920-00
CO2-O2 (CO2 >7%) Gray/Green F 6-121111-00 F 6-233121-00 F 6-230921-00
O2 -CO2 (CO2<7%) Green/Gray F 6-121112-00 F 6-233122-00 F 6-230922-00
He-O2 (He > 80%) Brown/Green F 6-121113-00 F 6-233123-00 F 6-230923-00
O2 -He (He < 80%) Green/Brown F 6-121114-00 F 6-233124-00 F 6-230924-00
Series B O2 White F 6-121100-00 F 6-233110-00 F 6-230910-00
DISS N2O Blue F 6-121101-00 F 6-233111-00 F 6-230911-00
(International) AIR Black/White F 6-151012-00 F 6-233116-00 F 6-230917-00
VAC Yellow F 6-151013-00 F 6-233117-00 F 6-230918-00
N2 Black F 6-121104-00 F 6-233114-00 F 6-230914-00
Instrument Air Red F 6-121108-00 F 6-233118-00 F 6-230916-00
WAGD Purple F 6-121109-00 F 6-233119-00 F 6-230919-00
CO2 Gray F 6-121110-00 F 6-233120-00 F 6-230920-00
Miscellaneous Slide* F 6-120978-00
Blank, Gas F 6-120979-00
Duplex Electrical Receptacle (Gray) F 6-120972-00
Trim Plate (5") F 6-325161-00
*Good design practice should include a slide for each vacuum outlet.

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SSB-840-03
Page 2 of 2
2/01/2006

Series B DISS Wall Assembly

DISS Outlet Optional Assemblies

Page 24 BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SERIES B DISS
SSB-840-04

CONSOLES
Page 1 of 2
2/01/06

Series B Console and Modular Headwall Medical Gas Outlet

DISS Key Style
SPECIFICATION

DISS Medical Gas Outlet

The DISS Medical Gas outlets for consoles and modular walls
shall be gas specific for the services indicated and accept only
corresponding DISS nuts and nipples. The outlets shall be UL
listed, CSA certified, and be fully compliant with the latest
edition of NFPA 99. All outlets shall be 100% tested for flow,
leaks and connector attachment. The outlets shall be cleaned
for oxygen service prior to shipping. The outlets shall be made
in the U.S.A. A die cast, light gray, epoxy powder coated or
plastic trim plate (optional) can be provided to trim each outlet
assembly.
Outlet Design
A complete medical gas outlet shall consist of a gas-specific
rough-in assembly and a matching gas-specific latch-valve
assembly.
Rough-in Assembly
The rough-in assembly shall be of modular design and include
a gas-specific 16-gauge steel mounting plate designed to
permit on-site installation. A machined brass outlet block shall
be permanently attached to the mounting bracket to permit the
1/2" OD (3/8" nominal), type-K copper inlet tube to swivel
360° for attachment to the piping system.
Gas service identification shall be affixed to the inlet tube and
the face of the mounting plate. A secondary valve shall be
installed in the outlet block of the rough-in assembly for both
pressure testing and preventing gas flow (except vacuum and
WAGD) when the latch-valve assembly is removed for
service. The rough-in assembly shall contain a double seal to
prevent gas leakage between the rough-in and latch-valve
assemblies after the wall is finished. A single o-ring seal shall
not be acceptable.
Latch Valve Assembly
The latch-valve assembly shall include an o-ring seal primary
valve and shall be indexed to the corresponding gas service
rough-in assembly to avoid accidental cross-connection. Latch
valves shall telescope up to 3/4" to allow for variation in wall
thickness. A metal cover plate insert with permanent
color-coded gas service identification shall be included as part
of the latch valve assembly.

Item Standard Console

Gas Service Color Code Complete Assembly* Latch-Valve Assembly Rough-in Assembly
O2 White F 6-121050-00 F 6-230910-00 F 6-233010-00
N2O Blue N/A F 6-230911-00 F 6-233011-00
AIR Yellow F 6-121052-00 F 6-230912-00 F 6-233012-00
Series B
VAC White F 6-121053-00 F 6-230913-00 F 6-233013-00
DISS
(U.S.) Inst Air Red N/A F 6-230916-00 F 6-233018-00
WAGD Purple N/A F 6-230919-00 F 6-233019-00
N2 Black N/A F 6-230914-00 F 6-233014-00
CO2 Gray N/A F 6-230920-00 F 6-233020-00
Series B O2 White N/A F 6-230910-00 F 6-233010-00
DISS AIR Black/White N/A F 6-230917-00 F 6-233016-00
(International)
VAC Yellow N/A F 6-230918-00 F 6-233017-00
Slide F 6-135012-00
Miscellaneous Blank, Gas F 6-415169-00

*Complete assembly consists of a rough-in assembly and latch-valve assembly. Optional trim plate must be ordered separately.

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 25
 SSB-840-04
Page 2 of 2
2/01/06

Series B DISS Console Assembly

Optional assemblies shown with optional 5” trim plate

Page 26 BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SSB-850-01
Page 2 of 2
2/01/06

Gas Control Panels

HORIZONTAL
CONTROL
PANEL

VERTICAL
CONTROL
PANEL

BeaconMedæs Š 14408 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 27
Page 28
 SSB-890-01

ASSEMBLIES
Page 1 of 7

HOSE
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION

Fittings and Components Gas Specific DISS Nipples

All BeaconMedaes DISS valves, bodies, nuts and nipples are
manufactured to comply with the latest edition of CGA V-5,
Diameter Index Safety System (Non-interchangeable low
pressure connections for medical gas applications)
Gas Specific DISS Valve or DISS Body
DISS BODY: When the DISS nut and nipple are disconnected
gas will continue to flow.
DISS VALVE: Contains a valve mechanism and begins to flow
gas when the DISS nut and nipple are connected and stops flow
when the DISS nut and nipple are disconnected.
The gas specific DISS nipple mates with the gas specific DISS
valve or valve body. They are supplied with O-rings where
required and are available with 1/4 -18 NPT male threads,
1/8 -27 NPT male threads or barbed ends for installation in
hose assemblies
DISS Nut
The DISS nut is used to secure the DISS nipple to the valve or
valve body. Often times the DISS nut may be used on several
different gases. The valve or body and the nipple are the
components to make the system gas specific.

DISS valves and valve bodies are available with 1/4 -18 NPT
male threads, 1/8 -27 NPT male threads or barbed ends for For assistance in determining the components you may require,
installation in hose assemblies please call 1-888-4MEDGAS to speak with one of our
specialists.

HOSE ASSEMBLIES
To order hose assemblies:
1. Select the fitting for each end of the hose assembly-one from (A) and one from (C) using the matrix shown.
2. Choose the appropriate part number according to the gas service required (B).
3. Replace the XX with a two-digit number from the chart (D). This two-digit number corresponds with the length of the hose required.
Example: A hose assembly for oxygen that is five feet long and uses a Geometric valve on one end and a Diameter-Index Safety System
(DISS) nut and nipple on the other end would carry a part number of 6-139103-05
NOTE:
Maximum length is thirty feet. Unless otherwise specified, all assemblies utilize 1/4” ID hose.

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 29
 SSB-890-01

ASSEMBLIES
Page 2 of 7

HOSE
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)

C
HOSE ASSEMBLIES

DISS nut and nipple Geometric adapter

Latch Key adapter Pin Index adapter
A B
Schrader quick-connect
N2 6-132184-XX

O2 6-132106-XX 6-132026-XX 6-132500-XX

N2O 6-132107-XX 6-132027-XX 6-132501-XX
DISS nut and nipple
AIR 6-132110-XX 6-132028-XX 6-132502-XX
VAC 6-132111-XX 6-132029-XX 6-123503-XX
N2 6-132112-XX
CO2 6-132118-XX
WAGD 6-132364-XX 6-132401-XX 6-132504-XX
O2 6-139103-XX 6-139012-XX
Geometric valve N2O 6-139105-XX 6-139013-XX
AIR 6-139109-XX 6-139014-XX
VAC 6-139108-XX 6-139015-XX
VAC 5/16” ID 6-139500-XX 6-139501-XX
WAGD 6-139366-XX 6-139340-XX
O2 6-139380-XX 6-139391-XX
Pin Index valve N2O 6-139381-XX 6-139392-XX
AIR 6-139382-XX 6-139393-XX
VAC 6-139383-XX 6-139394-XX
VAC 5/16” ID 6-139502-XX 6-139503-XX
WAGD 6-139384-XX 6-139395-XX
O2 6-139370-XX 6-139396-XX
Latch Key valve N2O 6-139371-XX 6-139397-XX
AIR 6-139372-XX 6-139398-XX
VAC 6-139373-XX 6-139399-XX
VAC 5/16” ID 6-139504-XX 6-139505-XX
WAGD 6-139374-XX 6-139400-XX
O2 6-139140-XX 6-139016-XX
N2O 6-139141-XX 6-139017-XX
DISS male valve
AIR 6-139142-XX 6-139018-XX
VAC 6-139143-XX 6-139019-XX
VAC 5/16” ID 6-139506-XX 6-139507-XX
N2 6-139144-XX
WAGD 6-139149-XX 6-139390-XX
CO2 6-139385-XX

Refer to the table below for overall length of hose assembly. Use the numbers in the XX column to denote hose length.
D
XX HOSE LENGTH1 (ft) XX HOSE LENGTH1 (ft) XX HOSE LENGTH2 (in) NOTE
1
01 1 09 9 31 32” XX numbers 01 through 30 represent hose length
02 2 10 10 32 38” in feet.
03 3 11 11 33 44” DOES NOT INCLUDE END FITTINGS.
2
04 4 12 12 34 50” XX numbers 31 through 36 represent special
05 5 15 15 35 56” application sizes (ceiling drop hoses) in inches.
06 6 22 22 36 68” INCLUDES END FITTINGS.
08 8 30 30

Page 30 BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SSB-890-01

ASSEMBLIES
Page 3 of 7

HOSE
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)
VALVES
The check valves below operate smoothly and are available with U.S. or international color coding. Gas-specific components are
permanently indexed to prevent accidental incorrect assembly.
NOTE: Unless otherwise specified, hose barb check valves are for 1/4” ID hose

Geometric DISS Valve Pin Index Latch Key

HOSE BARB CONNECTION

Gas Geometric DISS Pin Index Latch Key
Oxygen 6-121200-10 6-121201-10 6-121202-10 6-121203-10
Nitrous Oxide 6-121200-11 6-121201-11 6-121202-11 6-121203-11
Air 6-121200-12 6-121201-12 6-121202-12 6-121203-12
Vacuum 6-121200-13 6-121201-13 6-121202-13 6-121203-13
Vacuum 5/16” ID hose 6-121200-53 6-121201-53 6-121202-53 6-121203-53
Nitrogen 6-121201-14
Instrument Air 6-121201-18
WAGD 6-121200-19 6-121201-19 6-121202-19 6-121203-19
Carbon Dioxide 6-121201-20

INTERNATIONAL COLOR CODING

Oxygen 6-121200-15 6-121201-15 6-121202-15 6-121203-15
Air 6-121200-16 6-121201-16 6-121202-16 6-121203-16
Vacuum 6-121200-17 6-121201-17 6-121202-17 6-121203-17
Vacuum 5/16” ID hose 6-121200-57 6-121201-57 6-121202-57 6-121203-57

Geometric DISS Valve Pin Index Latch Key

1/4 - 18 NPT CONNECTION

Gas Geometric DISS Pin Index Latch Key
Oxygen 6-121210-10 6-121211-10 6-121212-10 6-121213-10
Nitrous Oxide 6-121210-11 6-121211-11 6-121212-11 6-121213-11
Air 6-121210-12 6-121211-12 6-121212-12 6-121213-12
Vacuum 6-121210-13 6-121211-13 6-121212-13 6-121213-13
Nitrogen 6-121211-14
Instrument Air 6-121211-18
WAGD 6-121210-19 6-121211-19 6-121212-19 6-121213-19
Carbon Dioxide, CO2-O2 6-121211-20
O2-CO2 6-121211-22
Helium, He-O2 6-121211-23
O2-He 6-121211-24

INTERNATIONAL COLOR CODING

Oxygen 6-121210-10 6-121211-10 6-121212-15 6-121213-15
Air 6-121210-16 6-121211-12 6-121212-16 6-121213-16
Vacuum 6-121210-17 6-121211-13 6-121212-17 6-121213-17

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 31
 SSB-890-01

ASSEMBLIES
Page 4 of 7

HOSE
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)
VALVES (continued)

Geometric DISS Valve Pin Index Latch Key

1/8 - 27 NPT CONNECTION
Gas Geometric DISS Pin Index Latch Key
Oxygen 6-121208-10
Nitrous Oxide 6-121208-11
Air 6-121208-12
Nitrogen 6-121208-14

DISS FITTINGS

DISS NIPPLES WITH O-RINGS TO MALE PIPE THREAD

PART NUMBER DESCRIPTION
NUT NIPPLE
6-825000-00 6-510016-00 Nipple, oxygen with o-ring to 1/8 -27 NPT male
6-511511-00 6-511605-00 Nipple, nitrous oxide with o-ring to 1/4 -18 NPT male
6-511511-00 6-511604-00 Nipple, air nipple with o-ring to 1/4 -18 NPT male
6-511511-00 6-512070-01 Nipple, vacuum with o-ring to 1/4 -18 NPT male
6-511511-00 6-511603-00 Nipple, nitrogen with o-ring to 1/4 -18 NPT male
6-511518-00 6-511620-00 Nipple, instrument air with o-ring to 1/4 -18 NPT male
6-511510-00 6-510079-00 Nipple, WAGD with o-ring to 1/8 -27 NPT male
6-511511-00 6-511612-00 Nipple, carbon dioxide, CO2-O2 mixture with o-ring to 1/4 -18 NPT male
6-511511-00 6-511614-00 Nipple, O2-CO2 mixture with o-ring to 1/4 -18 NPT male
6-511511-00 6-511616-00 Nipple, helium, He-O2 mixture with o-ring to 1/4 -18 NPT male
6-511511-00 6-511617-00 Nipple, O2-He with o-ring to 1/4 -18 NPT male

DISS NUT AND NIPPLE ASSEMBLIES WITH O-RINGS TO 1/8 -27 NPT MALE THREADS
PART NUMBER DESCRIPTION

6-121209-10 Assembly, oxygen nut and nipple with o-ring to 1/8 -27 NPT
6-121209-11 Assembly, nitrous oxide nut and nipple with o-ring to 1/8 -27 NPT
6-121209-12 Assembly, air nut and nipple with o-ring to 1/8 -27 NPT
6-121209-13 Assembly, vacuum nut and nipple with o-ring to 1/8 -27 NPT
6-121209-14 Assembly, nitrogen nut and nipple with o-ring to 1/8 -27 NPT
6-121209-19 Assembly, WAGD nut and nipple with o-ring to 1/8 -27 NPT
6-121209-20 Assembly, carbon dioxide nut and nipple with o-ring to 1/8 -27 NPT

Page 32 BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SSB-890-01
Page 5 of 7
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)
QUICK-CONNECT FITTINGS
GEOMETRIC QUICK-CONNECT ADAPTERS WITH PIPE THREADS
PART NUMBER DESCRIPTION
6-512013-00 Adapter, oxygen, 1-3/4” long, with 1/4 –18 NPT male thread
6-512001-00 Adapter, nitrous oxide, with 1/4 –18 NPT male thread
6-210636-00 Adapter, air, 1-3/4” long, non-swivel, with 1/4 –18 NPT male thread
6-512003-00 Adapter, vacuum, with 1/4 –18 NPT male thread

6-512092-00 Adapter, oxygen, with 1/8 –27 NPT male thread

6-512094-00 Adapter, vacuum, with 1/8 –27 NPT male thread

6-512542-00 Adapter, oxygen, 2-15/16” long, with 1/4 –18 NPT male thread
6-230338-00 Adapter, air, 2-15/16” long, with 1/4 –18 NPT male thread
6-230348-00 Adapter, WAGD, 2-15/16” long, with 1/4 –18 NPT male thread

GEOMETRIC QUICK-CONNECT ADAPTER WITH DISS THREAD

6-512019-00 Adapter, oxygen, with 9/16 –18 DISS male thread

PIN INDEX QUICK-CONNECT ADAPTERS

6-230625-00 Adapter, oxygen, with 1/4 –18 NPT male thread
6-230624-00 Adapter, oxygen, International, with 1/4 –18 NPT male thread
6-230627-00 Adapter, air, with 1/4 –18 NPT male thread
6-230628-00 Adapter, vacuum, with 1/4 –18 NPT male thread

6-231025-00 Adapter, oxygen, with 1/8 –27 NPT male thread

6-231027-00 Adapter, air, with 1/8 –27 NPT male thread
6-231029-00 Adapter, vacuum, with 1/8 –27 NPT male thread

LATCH KEY QUICK-CONNECT ADAPTERS

6-231030-00 Adapter, oxygen, round striker, with 1/4 –18 NPT male thread
6-231032-00 Adapter, air, rectangular striker, with 1/4 –18 NPT male thread
6-231034-00 Adapter, vacuum, rectangular striker, with 1/4 –18 NPT male thread

DISS BODY ADAPTERS

PART NUMBER DESCRIPTION

6-513001-00 Adapter, oxygen, with 1/4 –18 NPT male thread

6-511554-00 Adapter, nitrogen, with 1/4 –18 NPT male thread

6-520287-00 Adapter, vacuum, with 1/4 –18 NPT male thread
6-520395-00 Adapter, nitrous oxide, with 1/4 –18 NPT male thread
6-520396-00 Adapter, air, with 1/4 –18 NPT male thread
6-515606-00 Adapter, WAGD, with 1/4 –18 NPT male thread
6-511558-00 Adapter, instrument air with 1/4-18 NPT male thread
6-520288-00 Adapter, CO2 and CO2-O2 mixtures with 1/4 -18 NPT male threads

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 33
 SSB-890-01
Page 6 of 7
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)
HOSE BARB ADAPTERS, HOSE RETRACTORS, BULK HOSES, AND FERRULES

Geometric DISS Pin Index Latch Key

HOSE BARB ADAPTERS FOR 1/4” ID HOSE

Geometric DISS
Gas Geometric Pin Index Latch Key
With Ferrule Nipple w/O-ring Nut
Oxygen 6-210221-00 6-512007-00 6-512076-00 6-825000-00 6-231016-00 6-232114-00
Nitrous Oxide 6-210220-00 6-512018-00 6-511611-00 6-511511-00 6-232129-00 6-232115-00
Air 6-210222-00 6-230339-00 6-511609-00 6-511511-00 6-231018-00 6-232116-00
Vacuum 6-210223-00 6-512009-00 6-512077-00 6-511511-00 6-231017-00 6-232117-00
Nitrogen 6-511610-00 6-511511-00
Instrument Air 6-511621-00 6-511518-00
WAGD 6-230350-00 6-511515-00 6-511510-00 6-232139-00 6-232118-00
Carbon Dioxide 6-511607-00 6-511511-00

HOSE BARB ADAPTERS FOR 5/16” ID HOSE

Fittings and Components
DISS
Gas Geometric
Nipple w/O-ring Nut Unless otherwise indicated, the fittings and
Vacuum 6-512115-00 6-134157-00 6-511511-00 components listed in this catalog are designed for low
WAGD 6-230349-00 6-511606-00 6-511510-00 pressure medical gas systems where pressure does not
exceed 200 psig. In addition to fittings and
HOSE RETRACTOR components that utilize geometric shape indexing and
DISS connections, a complete offering of general
purpose fittings is also available.
Heavy Duty, Double Retractor for
all Pressure and Vacuum Service 6-132002-00 Caution:
Common threads, crimp or slip-fit connections
permit the assembly of components which may
permit the cross-indexing of services, unanticipated
BULK HOSE 1/4” ID (Length sold per foot) performance, poor flow, and excessive pressure
drops. The user is cautioned to consider such
Gas Service Color Code Part Number
factors when using these components.
Oxygen Green 6-611044-02
Nitrous Oxide Blue 6-611044-01 BeaconMedæs fittings and components are medical-
Air Yellow 6-611044-03 grade fittings, carefully machined to precise
Vacuum White 6-611044-04 dimensions, and offer outstanding durability.
WAGD Purple 6-611044-05
Nitrogen Black 6-611044-00
All Others Black 6-611044-00
5/16” ID
Vacuum White 6-656010-06

FERRULES
For 1/4” ID Hose (pressure) 6-355021-00
For 5/16” ID Hose (vacuum) 6-405000-00
Ferrule Hand Crimping Tool 6-995508-00

Page 34 BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088
 SSB-890-01

ASSEMBLIES
Page 7 of 7

HOSE
8/1/06

Hose Assemblies, Valves, Fittings, and Components

SPECIFICATIONS AND ORDERING INFORMATION (continued)
FITTINGS AND COUPLINGS

HOSE/TUBING FITTINGS

6-512012-00 Connector, hose barb for 1/4” ID hose, to 1/4 –18 NPT female thread
6-512506-00 Connector, hose barb for 5/16” ID hose, to 1/4 –18 NPT female thread

6-512508-00 Connector, hose barb for 5/16” ID hose, to 1/4 –18 NPT male thread
6-515002-00 Connector, hose barb for 1/4” ID hose, to 1/4 –18 NPT male thread

DISS BODY WITH HOSE BARB

6-520174-00 Adapter, oxygen, for 1/4” ID hose

6-525300-53 Adapter, vacuum, large bore, for 5/16” ID hose

6-525298-00 Adapter, nitrous oxide, for 1/4” ID hose

6-525299-00 Adapter, air, for 1/4” ID hose
6-525300-00 Adapter, vacuum, for 1/4” ID hose
6-525302-00 Adapter, nitrogen, for 1/4” ID hose
6-525303-00 Adapter, WAGD, for 1/4” ID hose
6-525301-00 Adapter, carbon dioxide, for 1/4” ID hose

COUPLINGS AND BUSHINGS

6-835020-00 Coupling, 1/4 –18 NPT female each end

6-513011-00 Coupling, 1/4 –18 NPT female to 1/8 –27 NPT female

6-513003-00 Coupling, 1/4 –18 NPT male thread x 1/8 -27 NPT male thread

6-835000-00 Bushing, 1/4 –18 NPT male to 1/8 –27 NPT female

6-835001-00 Coupling, 1/4 –18 NPT female thread x 1/8 -27 NPT male

BeaconMedæs Š 14408 W. 105th Street Lenexa, KS 66215 Š Phone: (913) 894-6058 Fax: (913) 894-6088 Page 35
Page 36
 ®

A company within the Atlas Copco Group

13325 Carowinds Blvd • Charlotte, NC 28273 • Phone 1 888 4 MED GAS • Fax 704 588 4949
www.beaconmedaes.com Page 37
Lessons Learned
from Natural Gas STAR Partners
Convert Gas Pneumatic Controls To
Instrument Air
Executive Summary
Pneumatic instrument systems powered by high-pressure
natural gas are often used across the natural gas and
petroleum industries for process control. Typical process
control applications include pressure, temperature, liquid
level, and flow rate regulation. The constant bleed of
natural gas from these controllers is collectively one of the
largest sources of methane emissions in the natural gas
industry, estimated at approximately 51 billion cubic feet
(Bcf) per year in the production sector, 14 Bcf per year in
the transmission sector, and <1 Bcf from processing.
Companies can achieve significant cost savings and
methane emission reductions by converting natural gas-
powered pneumatic control systems to compressed
instrument air systems. Instrument air systems
substitute compressed air for the pressurized natural gas,
eliminating methane emissions and providing additional
safety benefits. Cost effective applications, however, are
limited to those field sites with available electrical power,
either from a utility or self-generated.
Natural Gas STAR Partners have reported savings of up to
70,000 thousand cubic feet (Mcf) per year per facility by
replacing natural gas-powered pneumatic systems with
instrument air systems, representing annual savings of up
to $490,000 per facility. Partners have found that most
investments to convert pneumatic systems pay for
themselves in just over one year. Individual savings will
vary depending on the design, condition and specific
operating conditions of the controllers.
Economic and Environmental Benefits
Volume of
Method for Reducing Natural Gas
Natural Gas Losses Savings (Mcf/
year)
Replace Gas with Air in
Pneumatic Systems 20,000
(per facility)
General Assumptions:
a Cost of installing compressor, dryer and other accessories, and annual electricity requirements.
Technology Background
The natural gas industry uses a variety of process control
devices to operate valves that regulate pressure, flow,
temperature, and liquid levels. Most instrumentation and
control equipment falls into one of three categories: (1)
pneumatic; (2) electrical; or (3) mechanical. In the vast
majority of applications, the natural gas industry uses
pneumatic devices, which make use of readily available
high-pressure natural gas to provide the required energy
and control signals. Pneumatic instrument systems
powered by high-pressure natural gas are used throughout
the natural gas industry. In the production sector, an
estimated 400,000 pneumatic devices control and monitor
gas and liquid flows and levels in dehydrators and
separators, temperature in dehydrator regenerators, and
pressure in flash tanks. Most processing plants already
use instrument air, but some use gas pneumatics, and
including the gathering/booster stations that feed these
processing plants, there are about 13,000 gas pneumatic
devices in this sector. In the transmission sector, an
estimated 85,000 pneumatic devices actuate isolation
valves and regulate gas flow and pressure at compressor
stations, pipelines, and storage facilities. Non-bleed
pneumatic devices are also found on meter runs at
distribution company gate stations and distribution grids
where they regulate flow and pressure.
Exhibit 1 depicts a pneumatic control system powered by
natural gas. The pneumatic control system consists of the
process control instruments and valves that are operated
by natural gas regulated at approximately 20-30 pounds
Value of Natural Gas Savings ($/
Payback (Months)
year) Implemen-
tation Cost ($)a $3 per $5 per $7 per
$3 per Mcf $5 per Mcf $7 per Mcf
Mcf Mcf Mcf
$60,000 $100,000 $140,000 $60,000 12 8 6
1
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)
Exhibit 1: Natural Gas Pneumatic
Control System
per square inch (psi), and a network of distribution tubing
to supply all of the control instruments. Natural gas is
also used for a few “utility services,” such as small
pneumatic pumps, compressor motor starters, and
isolation shutoff valves. Exhibit 2 shows a simplified
diagram of a pneumatic control loop. A process condition,
such as liquid level in a separator vessel, is monitored by a
float that is mechanically linked to the liquid level
controller outside the vessel. A rise or fall in liquid level
moves the float upward or downward, which is translated
to small needle valves inside the controller. Pneumatic
supply gas is either directed to the valve actuator by the
needle valve pinching off an orifice, or gas pressure is bled
off the valve actuator. Increasing gas pressure on the
valve actuator pushes down a diaphragm connected by a
rod to the valve plug, causing the plug to open and
increasing the flow of liquid draining out of the separator
vessel. Gas pressure relieved from the valve actuator
allows a spring to push the valve plug closed.
As part of normal operation, natural gas powered
pneumatic devices release or bleed gas to the atmosphere
and, consequently, are a major source of methane
emissions from the natural gas industry. Pneumatic
control systems emit methane from tube joints, controls,
and any number of points within the distribution tubing
network. The actual bleed rate or emissions level largely
depends on the design of the device. In general, controllers
of similar design have similar steady-state bleed rates
regardless of brand name. The methane emission rate will
Exhibit 2: Signal and Actuation Schematics
also vary with the pneumatic gas supply pressure,
actuation frequency, and age or condition of the
equipment.
Many Partners have found that it is economic to substitute
compressed air for natural gas in pneumatic systems. The
use of instrument air eliminates methane emissions and
leads to increased gas sales. In addition, by eliminating
the use of a flammable substance, operational safety is
significantly increased. The primary costs associated with
conversion to instrument air systems are initial capital
expenditures for installing compressors and related
equipment and operating costs for electrical energy to
power the compressor motor. Existing pneumatic gas
supply piping, control instruments, and valve actuators of
the gas pneumatic system can be reused in an instrument
air system.
A compressed instrument air system is shown in Exhibit 3.
In these systems, atmospheric air is compressed, stored in
a volume tank, filtered and dried for instrument use. Air
used for utility services (e.g. small pneumatic pumps, gas
compressor motor starters, pneumatic tools, sand blasting)
does not need to be dried. All other parts of a gas
pneumatic system will work the same way with air as they
do with gas.
The major components of an instrument air conversion
project include the compressor, power source, dehydrator,
and volume tank. The following are descriptions of each of
2
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)
Exhibit 3: Compressed Instrument Air System
these components along with important installation
considerations.
Compressor. Compressors used for instrument air
delivery are available in various types and sizes, from
rotary screw (centrifugal) compressors to positive
displacement (reciprocating piston) types. The size of
the compressor depends on the size of the facility, the
number of control devices operated by the system,
and the typical bleed rates of these devices. The
compressor is usually driven by an electric motor
that turns on and off, depending on the pressure in
the volume tank. For reliability, a full spare
compressor is normally installed.
Power Source. A critical component of the
instrument air control system is the power source
required to operate the compressor. Because high-
pressure natural gas is abundant and readily
available, gas pneumatic systems can run
uninterrupted on a 24-hour, 7-day per week schedule.
The reliability of an instrument air system, however,
depends on the reliability of the compressor and
electric power supply. Most large natural gas plants
have either an existing electric power supply or have
their own power generation system. For smaller
facilities and remote locations, however, a reliable
source of electric power can be difficult to assure. In
some instances, solar-powered battery-operated air
compressors can be cost effective for remote locations,
which reduces both methane emissions and energy
consumption. Small natural gas powered fuel cells
are also being developed.
Dehydrators. Dehydrators, or air dryers, are an
integral part of the instrument air compressor
system. Water vapor present in atmospheric air
condenses when the air is pressurized and cooled,
and can cause a number of problems to these
systems, including corrosion of the instrument parts
and blockage of instrument air piping and controller
orifices. For smaller systems, membrane dryers have
become economic. These are molecular filters that
allow oxygen and nitrogen molecules to pass through
the membrane, and hold back water molecules. They
are very reliable, with no moving parts, and the filter
element can be easily replaced. For larger
applications, desiccant (alumina) dryers are more
cost effective.
Volume Tank. The volume tank holds enough air to
allow the pneumatic control system to have an
uninterrupted supply of high pressure air without
having to run the air compressor continuously. The
volume tank allows a large withdrawal of compressed
air for a short time, such as for a motor starter,
pneumatic pump, or pneumatic tools, without
affecting the process control functions.
Economic and Environmental Benefits
Reducing methane emissions from pneumatic devices by
converting to instrument air control and instrumentation
systems can yield significant economic and environmental
benefits for natural gas companies including:
Financial Return From Reducing Gas Emission
Losses. Assuming a natural gas price of $7.00 per
Mcf, savings from reduced emissions can be
estimated at $840 per year per device or $490,000 or
more per year per facility. In many cases, the cost of
converting to instrument air can be recovered in less
than a year.
Increased Life of Control Devices and
Improved Operational Efficiency. Natural gas
used in pneumatic control devices and instruments
often contains corrosive gases (such as carbon dioxide
and hydrogen sulfide) that can reduce the effective
operating life of these devices. In addition, natural
3
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)
gas often produces by-products of iron oxidation,
which can plug small orifices in the equipment
resulting in operational inefficiencies or hazards.
When instrument air is used, and properly filtered
and dried, system degradation is reduced and
operating life is extended.
Avoided Use Of Flammable Natural Gas. Using
compressed air as an alternative to natural gas
eliminates the use of a flammable substance,
significantly increasing the safety of natural gas
processing plants and transmission and distribution
systems. This can be particularly important at
offshore installations, where risks associated with
hazardous and flammable materials are greater.
Lower Methane Emissions. Reductions in
methane emissions have been reported as high as
70,000 Mcf per facility annually, depending on the
device(s) and the type of control application.
Decision Process
The conversion of natural gas pneumatics to instrument
air system is applicable to all natural gas facilities and
plants. To determine the most cost-effective applications,
however, requires a technical and economic feasibility
study. The six steps outlined below, and the practical
example with cost tables, equations, and factors, can help
companies to evaluate their opportunities.
Step 1: Identify Possible Locations For Instrument Air
System Installations.
Most natural gas-operated pneumatic control systems can
be replaced with instrument air. Instrument air systems
will require new investments for the compressor,
dehydrator, and other related equipment, as well as a
supply of electricity. As a result, a first step in a
successful instrument air conversion project is screening
existing facilities to identify locations that are most
suitable for cost effective projects. In general, three main
factors should be considered during this process.
Decision Process for Converting Gas Pneumatic Devices to
Instrument Air:
1. Identify possible locations for system installations.
2. Determine optimal system capacity.
3. Estimate the project costs.
4. Estimate gas savings.
5. Evaluate the economics.
6. Develop an implementation plan.
Methane Content of Natural Gas
The average methane content of natural gas varies by natural gas
industry sector. The Natural Gas STAR Program assumes the
following methane content of natural gas when estimating
methane savings for Partner Reported Opportunities.
Production 79 %
Processing 87 %
Transmission and Distribution 94 %
Facility Layout. The layout of a natural gas facility
can significantly affect equipment and installation
costs for an instrument air system. For example,
conversion to instrument air might not be cost
effective at decentralized facilities where tank
batteries are remote or widely scattered. Instrument
air is most appropriate when used at offshore
platforms and onshore facilities where pneumatics
are consolidated within a relatively small area.
Number Of Pneumatics. The more pneumatic
controllers converted to instrument air, the greater
the potential for reduced emissions and increased
company savings. Conversion to instrument air is
most profitable when a company is planning a facility
-wide change.
Available Power Supply. Since most instrument
air systems rely on electric power for operating the
compressor, a cost-effective, uninterrupted electrical
energy source is essential. While major facilities
often have an existing power supply or their own
power generation system, many smaller and remote
facilities do not. For these facilities, the cost of power
generation generally makes the use of instrument air
unprofitable. In addition, facilities with dedicated
generators need to assess whether the generators
have enough available capacity to support an air
compression system, as the cost of a generator
upgrade can be prohibitive. Remote facilities should
examine alternatives for power generation, which
range from microturbines to solar power.
Step 2: Determine Optimal System Capacity.
Once project sites have been identified, it is important to
determine the appropriate capacity of the new instrument
air system. The capacity needed is a direct function of the
amount of compressed air needed to both operate the
pneumatic instrumentation and meet any utility air
requirements.
4
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

I n s t r u m e n t A i r Exhibit 4: Calculate Compressor Size for

Requirements. T h e Rule-of-Thumb
Converting Gas Pneumatics to Instrument Air
compressed air needs for the
pneumatic system are equivalent 1 cfm air/control loop Given: For an average size production site with pneumatics, glycol
dehydration, compression, 35 control loops, and an average of
to the volume of gas being used 10 cfm utility gas usage for pneumatic pumps and compressor
to run the existing instrumentation—adjusted for air engine starting.
losses during the drying process. The current volume
A = Total Compressed Air
of gas usage can be determined by a direct meter IAu = Instrument air use
reading (if a meter has been installed). In IAs = Instrument air supply
nonmetered systems, a conservative rule-of-thumb UAs = Utility air supply
for sizing air systems is one cubic foot per minute L = Control loops
(cfm) of instrument air for each control loop Rule-of-thumb: 1 cfm per control loop for estimating
(consisting of a pneumatic controller and a control instrument air systems.
Rule-of-thumb: 17% of air is bypassed in membrane dryers.
valve). Rule-of-thumb: 1/3 of total air used for instruments, 2/3 of
total air used for utility services.
The initial estimate of
instrument air needs should Rule-of-Thumb
Calculate: A = Air compressor capacity required.
A = IAs + UAs
then be adjusted to account for 17 percent of air input IAu = L * (1 cfm/loop)
air losses during the drying is consumed by the
membrane dryer IAs = IAu/(100% - % air bypassed in dryer)
process. Typically, the UAs = IAu * (fraction of utility air use) / (fraction of instrument air
membrane filters in the air dryer consume about 17 use)
A = (35*1) / (100% - 17%) + (35*1) * (2/3) / (1/3) = 112 cfm
percent of the air input. As a result, the estimated
volume of instrument air usage is 83 percent of the
total compressed air supply: i.e., divide estimated air Step 3: Estimate the Project Costs.
usage by 83 percent. Desiccant dryers do not
The major costs associated with installing and operating
consume air and therefore require no adjustment.
an instrument air system are the installation costs for
compressors, dryers, and volume tanks, and energy costs.
Utility Air Requirements. It
Rule-of-Thumb The actual installation costs will be a function of the size,
is common to use compressed air
location, and other location specific factors. A typical
for utility purposes, such as Pneumatic air uses: 1/3
for instrument air; 2/3 conversion of a natural gas pneumatic control system to
engine starters, pneumatic for utility air
compressed instrument air costs approximately $45,000 to
driven pumps, pneumatic tools
$75,000.
(e.g., impact wrenches), and sand blasting. Unlike
instrument air, utility air does not have to be dried.
To estimate the cost for a given project, all expenses
The frequency and volumes of such utility air uses
associated with the compressor, dryer, volume tank, and
are additive. Companies will need to evaluate these
power supply must be calculated. Most vendors are willing
other compressed air services on a site-specific basis,
to provide estimates of the equipment costs and
allowing for the possibility of expansion at the site. A
installation requirements (including compressor size,
general rule-of-thumb is to assume that the
motor horsepower, electrical power requirements, and
maximum rate of compressed air needed periodically
storage capacity). Alternatively, operators can use the
for utility purposes will be double the steady rate
following information on the major system components to
used for instrument air.
estimate the total installed cost of the instrument air
system.
Exhibit 4 illustrates how the instrument air compressor
size can be estimated. Using the rule-of-thumb of 1 cfm/
Compressor Costs. It is common to install two
control loop, the current gas usage would translate to
compressors at a facility (one operating and one
approximately 35 cfm of dry instrument air. Adjusting for
stand-by spare) to ensure reliability and allow for
the dryer's air consumption (17 percent of air input), the
maintenance and overhauls without service
total instrument air supply requirement will be 42 cfm.
interruptions. The capacity for each of the
Factoring in utility air needs of about 70 cfm, the project
compressors must be sufficient to handle the total
would require a total of 112 cfm of compressed air.
expected compressed air volume for the project (i.e.,
both instrument and utility air). Exhibit 5 presents

5
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

cost estimates for purchasing and servicing small, applications is a permeable membrane dryer. Larger
medium, and large compressors. For screw-type air systems can use multiple membrane dryers, or,
compressors, operators should expect to overhaul the more cost effectively, alumina bed desiccant dryers.
unit every 5 to 6 years. This normally involves Membrane dryers filter out oil mist and particulate
exchanging the compressor core for a rebuilt solids and have no moving parts. As a result, annual
compressor at a cost of approximately $3,929, with an operating costs are kept low. Exhibit 7 presents
additional $720 in labor expense and a $650 core equipment and service cost data for different size
exchange credit. dryers. The appropriate sized dryer would need to
accommodate the expected volume of gas needed for
the instrument air system.
Exhibit 5: Air Compressor Costs

Air Comp-
Equip-
Annual Service
Exhibit 7: Air Dryer Costs
Service Horse- ment
Volume ressor Service Life
Size power Costs
(cfm) Type ($/yr) (yrs)
($) Air Annual
Service Dryer Equipment
Volume Service
Recipro Size Type Cost ($)
Small 30 10 3,275a 434 1 (cfm) ($/yr)
-cating

Medium 125 Screw 30 16,371 868 5-6b

Small 30 membrane 1,964 724

Large 350 Screw 75 28,812 868 5-6b

Medium 60a membrane 5,893 2,894
a Cost included package compressor with a volume tank.
b Rebuilt compressor costs $3,929 plus $500 labor minus $500 core exchange credit.

Large 350 alumina 13,096 4,341

Volume Tank. Compressed air supply systems a Largest membrane size; use multiple units, larger volumes.
include a volume tank, which maintains a steady
pressure with the on-off operation of the air Using the equipment information described above, the
compressor. The rule-of-thumb in determining the total installed cost for a project can be calculated. Exhibit
size of the volume tank is 1-gallon capacity for each 8 illustrates this using the earlier example of a medium-
cfm of compressed air. Exhibit sized production facility with an instrument air
6 presents equipment costs for Rule-of-Thumb requirement of 42 cfm and a maximum utility air
small, medium, and large requirement of 70 cfm (for a total of 112 cfm of compressed
volume tanks. Volume tanks 1 gallon tank capacity/1 air). To estimate the installed cost of equipment, it is a
have essentially no operating cfm air common practice in industry to assume that installation
and maintenance costs. labor is equivalent to equipment purchase cost (i.e. double
equipment purchase cost to estimate the installed cost).
Air Dryer Costs. Because instrument air must be This would be suitable for large, desiccant dried
very dry to avoid plugging and corrosion, the instrument air systems, but for small, skid-mounted
compressed air is commonly put through a dryer. instrument air systems a factor of 1.5 is used to estimate
The most common dryer used in small to medium the total installed cost (installation labor is half the cost of
equipment).

Exhibit 6: Volume Tank Costs In addition to the facility costs, it is also necessary to
estimate the energy costs associated with operating the
Equipment Cost system. The most significant operating cost of an air
Service Size Air Volume (gallons)
($) compressor is electricity, unless the site has excess self-
generation capacity. To continue the example from above,
Smalla 80 655
assuming that electricity is purchased at 7.5 cents per
Medium 400 1,964 kilowatt-hour (kWh) and that one compressor is in standby
Large 1,000 3,929 while the other compressor runs at full capacity half the
time (a 50 percent operating factor), the electrical power
a Small reciprocating air compressors, 10 horsepower and less, are commonly supplied with a surge tank.

6
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

years to account for increased leakage associated with

Exhibit 8: Calculate Total Installation Costs wear and tear. Alternatively, installing a meter can be
more accurate, provided monitoring occurs over a long
Given:
enough period of time to take account of all the utility uses
Compressors (2) = $32,742 (Exhibit 5) of gas (i.e., pumps, motor starters, activation of isolation
Volume Tanks (2- = $1,310 (Exhibit 6)
small)
valves).
Membrane Dryer = $5,893 (Exhibit 7)
Installed Cost Factor = 1.5 EPA’s Lessons Learned: Options for Reducing Methane
Emissions from Pneumatic Devices in the Natural Gas
Calculate Total Installed Cost: Industry, provides brand name, model, and gas
Equipment Cost = Compressor Cost + Tank Cost + Dryer consumption information for a wide variety of currently
Cost used pneumatic devices. Manufacturer information and
= $32,742 + $1,310 + $5,893 actual field measurement data, wherever available, are
= $39,945 provided as well (see Appendix of that report). To simplify
Total Cost = Equipment Cost * Installation Cost the calculation of gas savings for the purpose of this lesson
Factor learned analysis, we can use the earlier rules-of-thumb to
= $39,945 * 1.5 estimate the gas savings. The gas savings for the medium-
= $59,917
sized production facility example in Exhibit 4 include the
conservatively estimated 35 cfm used in the 35 gas
cost amounts to $13,140 per year. This calculation is pneumatic controllers plus the gas used occasionally for
shown in Exhibit 9. compressor motor starters and small pneumatic chemical
and transfer pumps. (Note that replacing these gas usages
Step 4: Estimate Gas Savings. will result in direct savings of gas emissions.) Natural gas
is not used for pneumatic tools or sand blasting, so
To estimate the gas savings that result from the
additional compressed air provided for these services does
installation of an instrument air system, it is important to
not reduce methane emissions. Assuming an annual
determine the normal bleed rates (continuous leak from
average of 10 cfm gas use for natural gas powered non-
piping networks, control devices, etc.), as well as the peak
instrument services, the gas savings would be 45 cfm. As
bleed rates (associated with movements in the control
shown in Exhibit 10, this is equivalent to 23,652 Mcf per
devices). One approach is to list all the control devices,
year and annual savings of $165,600.

Exhibit 9: Calculate Electricity Cost Step 5: Evaluate the Economics.

Given: The cost effectiveness of replacing the natural gas

= 30 HP
pneumatic control systems with instrument air systems
Engine Power
Operating Factor (OF) = 50 percent

Electricity Cost = $0.075/kwh Exhibit 10: Calculate Gas Savings

Calculate Required Power:
Given:
Electrical Power = Engine Power * OF * Electricity Cost
Pneumatic instrument gas = 35 cfm
= [30 HP * 8,760 hrs/yr * 0.5 * $0.075/
usage
kwh] / 0.75 HP/kw
Other non-instrument gas = 10 cfm
= $13,140/yr
usage

assess their normal and peak bleed rates, frequency of Calculate Value of Gas Saved:
actuation, and estimates of leakage from the piping Volume of Natural Gas Saved = Instrument Usage + Other Usage
networks. Manufacturers of the control devices usually = 35 cfm + 10 cfm
publish the emission rates for each type of device, and for = 45 cfm
each type of operation. Rates should be increased by 25 Annual Volume of Gas Saved = 45 cfm * 525,600 min/yr / 1000
percent for devices that have been in service without = 23,652 Mcf/yr
overhaul for five to 10 years, and by about 50 percent for Annual Value of Gas Saved = volume * $7.00/Mcf
devices that have not been overhauled for more than 10 = 23,652 Mcf/yr * $7.00/Mcf
= $165,600/year

7
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

can be evaluated using straightforward cost-benefit

economic analyses. Nelson Price Indexes
In order to account for inflation in equipment and
Exhibit 11 illustrates a cost-benefit analysis for the operating & maintenance costs, Nelson-Farrar
medium-sized production facility example. The cash flow Quarterly Cost Indexes (available in the first issue of
over a five-year period is analyzed by showing the each quarter in the Oil and Gas Journal) are used to
magnitude and timing of costs from Exhibits 8 and 9 update costs in the Lessons Learned documents.
(shown in parentheses) and benefits from Exhibit 10. The
annual maintenance costs associated with the compressors The “Refinery Operation Index” is used to revise
and air dryer, from Exhibits 5 and 7, are accounted for, as operating costs while the “Machinery: Oilfield Itemized
well as a five-year major overhaul of a compressor per Refining Cost Index” is used to update equipment
Exhibit 5. The net present value (NPV) is equal to the costs.
benefits minus the costs accrued over five years and To use these indexes in the future, simply look up the
discounted by 10 percent each year. The Internal Rate of most current Nelson-Farrar index number, divide by
Return (IRR) reflects the discount rate at which the NPV the February 2006 Nelson-Farrar index number, and,
generated by the investment equals zero. finally multiply by the appropriate costs in the Lessons
Learned.
Step 6: Develop an Implementation Plan.
After determining the feasibility and economics of
minimize labor costs and disruption of operations. This
converting to an instrument air system, develop a
might include a parallel strategy to install low-bleed
systematic plan for implementing the required changes.
devices in conjunction with the switch to instrument air
This can include installing a gas measuring meter in the
systems. There are similar economic savings for
gas supply line, making an estimate of the number of
conserving instrument air use as for conserving methane
control loops, ensuring an uninterrupted supply of electric
emissions with low bleed pneumatic devices. Whenever
energy for operating the compressors, and replacing old,
specific pneumatic devices are being replaced, such as in
obsolete and high-bleed controllers. It is recommended
the case of alternative mechanical and/or electronic
that all necessary changes be made at one time to

Exhibit 11: Economic Analysis of Instrument Air System Conversion

Year 0 Year 1 Year 2 Year 3 Year 4 Year 5

Implementation Cost ($) (59,917)

(13,140)a (13,140) (13,140) (13,140) (13,140)
O&M Cost ($)
(4,630)b (4,630) (4,630) (4,630) (4,630)
Overhaul Cost ($) 0 0 0 0 0 (6,286)c

Total Cost ($) (59,917) (17,770) (17,770) (17,770) (17,770) (24,057)

d
Gas Savings ($) 0 165,600 165,600 165,600 165,600 165,600

Annual Cash Flow ($) (59,917) 147,830 147,830 147,830 147,830 141,543

Cumulative Cash Flow ($) (59,917) 87,912 235,742 383,571 531,401 672,944

Payback Period (months) 5

IRR 246%
e
NPV $496,570
a Electrical power at 7.5 cents per kilowatt-hour.
b Maintenance costs include $1,736 compressor service and $2,894 air dryer membrane replacement.
c Compressor overhaul cost of $3,929, inflated at 10% per year.
d Value of gas = $7.00/Mcf.
e Net Present Value (NPV) based on 10% discount rate for 5 years.

8
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

systems, the existing pneumatic devices should be replaced Exhibit 12: Gas Price Impact
on a similar economic basis as discussed in the companion on Economic Analysis
document Lessons Learned: Options for Reducing Methane
Emissions from Pneumatic Devices in the Natural Gas
$3/Mcf $5/Mcf $7/Mcf $8/Mcf $10/Mcf
Industry.
Value of
When assessing options for converting gas pneumatic Gas Saved
$70,971 $118,286 $165,600 $189,257 $236,571
controls to instrument air, natural gas price may influence
Payback
the decision making process. Exhibit 12 shows an Period 14 8 5 5 4
economic analysis installing two 30 hp compressors, two (months)
medium sized volume tanks, and a medium sized Internal
membrane dryer at different natural gas prices. Rate of
84% 166% 246% 286% 365%
Return
(IRR)
Partner Experiences Net
Present
$137,853 $317,211 $496,570 $586,249 $765,607
Value
Several EPA Natural Gas Star Partners have reported the (i=10%)
conversion of natural gas pneumatic control systems to
compressed instrument air systems as the single most
Other Technologies
significant source of methane emission reduction and a
source of substantial cost savings. Exhibit 13 below
highlights the accomplishments that several Natural Gas The majority of Partners' experiences in substituting
STAR Partners have reported. natural gas-powered pneumatic devices and control
instrumentation with alternative controllers have involved

Exhibit 13: Partner Reported Experience

Gas STAR Project Cost Annual Emissions

Description of Project Annual Savings ($/yr)a Payback (months)b
Partner ($) Reductions (Mcf/yr)

Installed an air compression

Unocalc (now system in its Fresh Water
$79,000 69,350 $485,450 2
Chevron) Bayou facility in southern
Vermillion Parish, Louisiana
Installed compressed air
Texacoc (now system to drive pneumatic
$52,000 23,000 $161,000 4
Chevron) devices in 10 South Louisiana
facilities
Converted pneumatic
$227,000 over 2
Chevronc controllers to compressed air, 31,700 $221,900 7
years
including new installations
Installed instrument air
d systems at 3 production
ExxonMobil $72,000 19,163 $134,141 7
satellites and 1 central tank
battery at Postle CO2 unit
Used instrument air operated
Shell devices on over 4,300 valves Not available 532,800 $3,729,600 Not available
at off-shore platforms
Installed 15 instrument air
Marathon systems in New Mexico Not available 120 - 38,000 per facility $840 - 226,000 Not available
facilities
a Value of gas = $7.00/Mcf.
b Calculated based on Partner-reported costs and gas savings updated to 2006 costs.
c Data for this report were collected prior to the Chevron-Texaco and Chevron-Unocal mergers.
d Data for this report were collected prior to the Exxon/Mobil merger in 1999.

9
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)
the installation of compressed instrument air systems.
Some additional alternatives to gas pneumatics
implemented by Partners are described below:
Liquid Nitrogen. In a system using liquid nitrogen,
the volume tank, air compressor, and dryer are
replaced with a cylinder containing cryogenic liquid
nitrogen. A pressure regulator allows expansion of
the nitrogen gas into the instrument and control-
piping network at the desired pressure. Liquid
nitrogen bottles are replaced periodically. Liquid
nitrogen-operated devices require handling of
cryogenic liquids, which can be expensive as well as a
potential safety hazard. Large volume demands on a
liquid nitrogen system require a vaporizer.
Mechanical Controls and Instrumentation
System. Mechanical instrument and control devices
have a long history of use in the natural gas and
petroleum industry. They are usually distinguished
by the absence of pneumatic and electric components,
are simple in design, and require no power source.
Such equipment operates using springs, levers,
baffles, flow channels, and hand wheels. They have
several disadvantages, such as limited application,
the need for continuous calibration, lack of
sensitivity, inability to handle large variations, and
potential for sticking parts.
Electric and Electro-Pneumatic Devices. As a
result of advanced technology and increasing
sophistication, the use of electronic instrument and
control devices is increasing. The advantage of these
devices is that they require no compression devices to
supply energy to operate the equipment; a simple 120
-volt electric supply is used for power. Another
advantage is that the use of electronic instrument
and control devices is far less dangerous than using
combustible natural gas or cryogenic liquid nitrogen
cylinders. The disadvantage of these devices is their
reliance on an uninterrupted source of electric
supply, and significantly higher costs.
Although these options have advantages, systems using air
instead of natural gas are the most widely employed
alternative in replacing natural gas-operated pneumatic
control devices. It is important to note that maintaining a
constant, reliable supply of dry, compressed air in a plant
environment is a significant cost, albeit more economic
than natural gas. Therefore, a parallel strategy to install
low-bleed devices in conjunction with the switch to
instrument air systems (refer to Lessons Learned: Options
for Reducing Methane Emissions from Pneumatic Devices
in the Natural Gas Industry), and to design a maintenance
schedule to keep the instruments and control devices in
tune, is often economic. Such actions can significantly
reduce the consumption of instrument air in the overall
system and, therefore, minimize both the size of the
compression system and the electricity consumption over
the life of the plant.
Lessons Learned
The lessons learned from Natural Gas STAR Partners are:
Installing instrument air systems has the potential to
increase revenues and substantially reduce methane
emissions.
Instrument air systems can extend the life cycle of
system equipment, which can accumulate trace
amounts of sulfur and various acid gases when
controlled by natural gas, thus adding to the
potential savings and increasing operational
efficiencies.
Remote locations and facilities without a reliable
source of electric supply often need to evaluate
alternate power generation sources. When feasible,
solar-powered air compressors provide an economical
and ecologically beneficial alternative to expensive
electricity in remote production areas. On site
generation using microturbines running on natural
gas is another alternative.
A parallel strategy of installing low-bleed devices in
conjunction with the switch to instrument air
systems is often economic.
Existing infrastructure can be used; therefore, no
pipe replacement is needed. However, existing
piping and tubing should be flushed clear of
accumulated debris.
Rotary air compressors are normally lubricated with
oil, which must be filtered to maintain the life and
proper performance of membrane dryers.
Use of instrument air will eliminate safety hazards
associated with flammable natural gas usage in
pneumatic devices.
Nitrogen-drive systems may be an alternative to
instrument air in special cases, but tends to be
10
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

expensive and handling of cryogenic gas is a safety

concern.

Report reductions in methane emissions from

converting gas pneumatic controls to instrument air
in your Natural Gas STAR Annual Report.

References

Adams, Mark. Pneumatic Instrument Bleed Reduction Strategy and

Practical Application, Fisher Controls International, Inc.1995.

Beitler, C.M., Reif, D.L., Reuter, C.O. and James M. Evans. Control
Devices Monitoring for Glycol Dehydrator Condensers: Testing and
Modeling Approaches, Radian International LLC, Gas Research
Institute, SPE 37879, 1997.

Cober, Bill. C&B Sales and Services, Inc. Personal contact.

Fisher, Kevin S., Reuter, Curtis, Lyon, Mel and Jorge Gamez. Glycol
Dehydrator Emission Control Improved, Radian Corp., Public Service
Co. of Colorado Denver, Gas Research Institute.

Frederick, James. Spirit Energy 76. Personal contact.

Games, J.P., Reuter, C.O. and C.M. Beitler, Field Testing Results for the R
-BTEX Process for Controlling Glycol Dehydrator Emissions, Gas
Research Institute, Radian Corporation, SPE 29742, 1995.

Gunning, Paul M. U.S. EPA Natural Gas STAR Program. Personal contact.

Gupta, Arun, Ansari, R. Rai and A.K. Sah. Reduction of Glycol Loss From
Gas Dehydration Unit At Offshore Platform in Bombay Offshore—A
Case Study, N.A.K.R. IOGPT, ONGC, India, SPPE 36225, 1996.

Reid, Laurance, S. Predicting the Capabilities of Glycol Dehydrators, SPE-

AIME, Laurance Reid Associates.

Scalfana, David B., Case History Reducing Methane Emissions From High
Bleed Pneumatic Controllers Offshore, Chevron U.S.A. Production Co.
SPE 37927, 1997.

Schievelbein, V.H., Hydrocarbon Recovery from Glycol Reboiler Vapor

With Glycol-Cooled Condenser, Texaco, Inc. SPE 25949. 1993.

Schievelbein, Vernon H. Reducing Methane Emissions from Glycol

Dehydrators, Texaco EPTD, SPE 37929, 1997.

Soules, J.R. and P.V. Tran. Solar-Powered Air Compressor: An

Economical and Ecological Power Source for Remote Locations, Otis
Engineering Corp. SPE 25550, 1993.

11
Convert Gas Pneumatic Controls To Instrument Air
(Cont’d)

United States
Environmental Protection Agency
Air and Radiation (6202J)
1200 Pennsylvania Ave., NW
Washington, DC 20460

October 2006

EPA provides the suggested methane emissions estimating methods contained in this document as a tool to develop basic methane emissions estimates only. As
regulatory reporting demands a higher-level of accuracy, the methane emission estimating methods and terminology contained in this document may not conform to
the Greenhouse Gas Reporting Rule, 40 CFR Part 98, Subpart W methods or those in other EPA regulations.

12