Welcome to the

World of PIONEER
Innovative Nature
PIONEER Air Systems was slar1ed in Spring of 1980. It was a l ime of deep recession
lor American industry. Out of necessity. we sought jobs thai most of our competitors did
nol want to or could nol handle. Soon, working with special products, thinking different -
Iy, and helping customers to solve thei r problems became second nature to us. This al-
titude gave birth to our slogan: equipment is our specialty." Among lhe
industry fi rsts introduced by PIONEER are:
1. ADA (After Cooler, Dryer and Reheater) Systems
2. Patented Triple Tube Heal Exchangers
3. MR. GOOD AlAE Systems
4. PERFECT-AlAE Systems
5. Multi-Stage Deliquescent and Refrigerant Dryers (deliver up 10 -40' F PDP)
6. FUTURE-AlAE Hybrid, Regenerative and Refrigerant Dryers
7. Oil-Free Air Systems
tn a lew years, PIONEER has become not only a major manufacturer but a leader in the
field of compressed air. Today there are over 15,000 PIONEER products and systems
in the field helping users solve their problems.
Awards and Patents
PIONEER has won numerous awards and patents including:
U.S. Patent No. 4,638,652 for Triple Tube Design heat exchanger.
U.S. Patent No. 4,761,968 for High Efficiency air drying system.
U.S. Patent No. 4,499,033 l or a High Efficiency coalescing medium.
"Top Honor" Vaaler Award for FUTUAE AlAE System.
Engineering Assistance
PIONEER designers, engineers, application engineers, inside sates staff, regional sales
representatives and factory-t rained distri butor sales engi neers are all available to work
with you in selecting and sizing the most appropriate products for your compressed ai r
system.
Our service personnel with in-depth factory training and field experience, are avail able
lor factory start-ups and service after the sale. They will help you achieve reliable pertor-
mance and maximum benefits from PIONEER products.
Availability of Products
The full line of PIONEER products are available through a network of authorized di s-
tributors in major cities and marketing areas. Call the PIONEER factory to locate the
authorized distributOf nearest you.
Disclaimer
The information in this booklet has been carefully prepared, however, PIONEER, its
employees and its officers make no warranties respecting it and disclaim any respon-
sibi lity or liabil ity of any kind for any loss or damage as a consequence of anyone's use
or reliance uporl such information. We encourage verification and further invesligalion
of the information contained herein.
Acknowledgements
Richard Harlan, Earl Brooks, Patricia Abbott and other PIONEER employees have been
very helpful in preparation of this manual.
Joie Rose and Mitch Brooks of Visual Impact have been very diligent and cooperative in
layout and design of this manual.
I si ncerely thank them for their eUorts.
I dedicate this publication to my parent s.
Sam Basseen, M.S.()
President & C.E.O.
PIONEER AIR SYSTEMS, INC.
Wartburg, TN
January 3, 1990
PIONEER - AN INNOVATIVE COMPANY 2
ThiS manual is wrillen as a guide for professionals working in the field of compressed
air. It offers helpful Information on the selection, sizing and installation of proper equip
ment for your compressed air system.
In a plant, the potential for damage and loss due 10 compressed air contaminants is
overwhelming. Contaminants damage air 100\S, instruments and controls resulting in ex-
cessive maintenance, down lime or even plant shut downs. Moreover, contaminants
may cause product or process spoilage.
A few minutes of your lime in reading this manual will help you seleclthe proper equip
ment and may save you lens of thousands of dollars.
Useful Definitions ............ ..................... .. ........... .................................... 4
Why Treat Compressed Air? .. .... .... ... .... .. ......... ... ..... ... ... .... ... .......... ..... 6
Contaminant Removal Equipment ........... ................... .. ... .. ... ........ ...... 6
A Reliable Compressed Air System .. ... ........................ ... ....... .... ... .. .... 7
Separators .............................................................................................. 8
Filtration .............. _ ............. ......................... ............................................ 9
Contaminant Removal by PIONEER Filters ...................................... 10
Filters and Adsorbers ..... ............... .. ..... ....... .. ..... ............ .................... 11
Deliquescent Dryers ....................................... ......................... ...... ..... 12
PIONEER Refrigerant Dryers .. ... ........................................................ 13
Regenerative Desiccants ................................................ ............ ... ... .. 15
Regenerative Dryers .. .............. ........ ..... ... .. ... .......... .. ... ....... ..... ..... ... ... 17
A Comparison of Regenerative Dryers ............ ................................. 18
Demand Cycte Control ..... ... ... .......... ................ ... ...... .. .... ....... .. .......... .. 19
Air Dryer Selection Table .. ... .................. .. ....... .......... ......................... 20
Water Cooling Systems ....... .. ..................... ... .............. ... ............ ....... . 20
Compressed Air Data .................. ..... ..... ......... ............... .... ... ............... 22
Useful Technical Data ................................................................. ... .... . 26
Useful Electrical Information .................................................. ....... .... 27
COMPAESSED AIR SYSTEMS GUIDE 3
Introduction
Contents
Useful Definitions
ABSORB To lake In and hold, not just on the surface, but deep Into the malerial, usual-
ly forming a mixture Qut of two or more substances.
ACTIVATED ALUMINA A regenerative desiccant.
ADIABETIC DRYING Drying without gain or loss of heat.
ADSORB To lake in and hold liquid and gas on the surface of a sol id but porous
male rial without causing a change in the basic structure of the material.
AFTER FIL TEA - A liller thai usually follows a dryer lor protection of down stream
equipment.
AMBIENT TEMPERATURE T emperalure of air surroundi ng the equipment.
AUTOMATIC ORAIN - A device that automatically discharges condensate.
BAR - A metric unit of pressure equal to 10
5
N/m
2
(newlons per square meter). One bar
approximately equals 14.5 PSIG.
BTU - British Thermal Uni t . a measure of heat or energy. One BTU Is the amount of
heat needed to raise temperature of one pound of water by one degree fahrenheit.
CAPILLARY - A device that controls flow of refrigerant.
COALESCE - To fuse, uni te or grow into a mass large enough to fall due to gravity.
COMPRESSED AIR DRYER - A device designed to lower the dew point 01 compressed
air.
COMPRESSOR, HERMETIC - A type of compressor in which the motor and the com-
pressor are contained In a si ngle pressure vessel. Because the systems are sealed
(welded construction) from the outside, the systems are not serviceable in the field.
COMPRESSOR, SEMI-HERMETIC Similar to a hermetic compressor except these
can be serviced in the field because they have bolted i nstead of welded construction.
COMPRESSOR, OPEN TYPE - Motor and compressor are two separate units. Motor
drives the compressor by direct couple, through beU(s) or through gear(s).
CONDENSATION - The process of changing vapor or gas inl o liquid.
CONTACT TIME - The amounl of time the compressed air comes in contact with desic-
cant in a compressed air dryer.
DESICCANT - A substance suitable for absorbing or adsorbing moisture.
DEW POINT - The temperature at which moisture begins to condense.
a. Atmospheric Dew Point - Dew point at atmospheric pressure.
b. Pressure Dew Point - Dew point at pressure.
NOTE: 11'1 selecting an air drying system only pressure dew point Is important because the com
pressed air is normally used at pl"essure.
DEW POINT SUPPRESSION - The reduction In dew point.
DRY BULB TEMPERATURE - The temperature of the air as indicated by an ordinary
thermometer.
DRYERS, DELIOUESCENT - Dryers that use a desiccant tower to dry the air. Typically
the desiccant is not regenerated and it is consumed in the dryi ng process.
DRYERS, REFRIGERATED - Dryers that use a refrigeration system to cool and
condense moisture.
DRYERS, REGENERATIVE Dryers thaI use two desiccant towers. One tower dries
the Incoming air while the other regenerates the desiccant.
DYNAMIC ADSORPTION - The process of adsorption In moving or flowing air. The
dynamic capacity of the desiccant to adsorb moisture is a function of the temperat ure
and pressure to which it is subjected.
EVAPORATOR - A heat exchanger where refrigerant absorbs heat and changes from
liquid to gas (evaporation).
EXPANSION VALVE - A valve that controls the flow of refrigerant.
FILTER - A device designed to remove solid and liquid particles.
FREE AIR Air at ambi ent temperature. pressure and relative humidity (or atmospheric
air al natural conditions).
HEAT EXCHANGER - A device capable of transferring heal from one place or medium
to another.
PIONEER - AN INNOVATIVE COMPANY 4
HOT GAS 8Y-PASS VALVE - A valve that by-passes hot refrigerant gas from high pres-
sure to the low pressure side of a refrigeration system. The valve is generall y used to
reduce refrigeration capacity to maintain a desired refrigerant temperature.
HUMIDITY, ABSOLUTE Mass of water vapor in per unit volume of air, usually
measured as grains/cu. II. or Ibs/cu. It. or grams/cu. It.
HUMIDITY, MOLAL - Mass 01 water vapor in Mots per Mole 01 air. The Molal composi-
tion of a mi Kture is proportional to its partial pressures.
HUMIDITY, RElATIVE - Rat io of the quantity of moisture present to the quantity that
will saturate the air at a gi ven temperature.
MICRON - One millionth of one meter or 1 meter " 1 ,000,000 microns.
MOISTURE SEPARATOR - A device that separates condensate from an air stream.
MOLE Amount of substance in elementary enti ties as atoms.
MOLECULAR SIEVE - A regenerative desiccant.
PARTIAL PRESSURE - The pressure that a gas will have If It occupies the total volume
of the gas miKture. The total pressure (P) of the miKture is the sum of the partial pres-
sures i.e. P = P, + P2 + P3 + .
PRECOOLERIREHEATER - A heat exchanger Ihatlowers the temperature of the inlet
air with the help of the outgoing cold air. In the process the outgoing air is reheated by
the incoming air.
PSI A (ABSOLUTE PRESSURE) - Sum of the atmospheric pressure and the gauge
pressure.
PSIG . Pounds per square inch of pressure as measured by a gauge.
PURGE - Usually refers to the removal of unwanted air or gas.
REFRI GERANT - A lIuid used for heattransler in a relrigeral ion unit. Freon 12, 22, and
502 are commonly used refrigerants.
REFRIGERANT ACCUMULATOR - A tank-li ke device used in a refrigeration system
that holds liquid refrigerant and all ows 1I0w of gas refrigerant.
REFRI GERANT CONDENSER - A heat exchanger that converts gas refrigerant into
liquid relrigerant in a refrigeration system.
REFRf GERANT RECEI VER - A storage lank for li quid refrigerant in a refrigeration
system.
REGENERATION - Reactivation of desiccant.
SATURATED AIR - Air at 100% relat ive humidity. II takes 7.S cu. It. of Iree ai r to
saturate compressed air at 100 PSIG, Therefore, as long as the atmospheric relative
humidity is over 12.9% (7.8 ~ 12.9 = 100%), which it almost always is, the compressed
air from an air compressor is saturated. (This also explains why an air dryer is a must
for a compressed air system).
SCFM - UStandard" Cubic Feet per Minute. "Standard" ai r is defined at 6S' F (20C).
14.7 PSI A (1.01 Bar) and 36% relative humidity (density, 0.0750 Ibs.lcu. ft. ).
SILICA GEL - A regenerat ive desiccant.
STATIC ADSORPTION - The process of adsorption in static or still air.
SUPERHEAT - The di fference between lhe actual refrigeranl temperature at the
evaporator outlet and the theoretical evaporation lemperature for the refriger ant pres
sure at the oulet.
TONS OF REFRIGERATION CAPACITV - One ton of refrigeration capaci ty equals
12,000 BTU/ HR.
VERI-ORI40 PLUS - PIONEER deliquescent desiccant.
WET-BUL8 TEMPERATURE - If a thermometer is covered with a wei cloth and eK-
posed to the atmosphere, the temperature read by it is lower because the evaporation
01 water cools the thermometer. This is called the 'Wet -Bulb Temperature" (also the
temperature read by a psychrometer). It is an indicator of the humidity (or lack of it) in
the air and lies between Dry-BUlb Temperature and dew point. Only at saturation is the
Wet -Bulb Temperature, the Dry-Bulb Temperature and the dewpoinl equal , otherwise
they are different.
COMPRESSED Al A SYSTEMS GUIDE 5
Why Treat
Compressed Air?
Contaminant
Removal
Equipment
Because it is economical. All pneumatically operated equipment is designed to operate
more efficiently and rel iably with clean, dry compressed air.
A compressor takes in atmospheric air thai is loaded with moisture, dirt , dust fibers and
bacteria. Due to constant use and often abuse, most compressors deliver large amounts
01 oil fumes along with compressed air. The hoi air delivered by a compressor carries
contaminants which cause corrosion, excessive wear, malfunction and ultimately failure
01 your compressed ai r components, tools and system. To assure a rel iable and effi-
cient operation of a plant, they must be removed.
Field lests prove thai a typical PIONEER system pays for itself In less than a year.
The chart below shows the most common contaminants present in compressed air and
the equipment sui table for their removal :
CONTAMINANTS REMOVAL EQUIPMENT
1. Condensed Moisture
Separator
Particul ate Filler
Coalescer Filter
Dryer
2. Moisture kI Aerosol or Mist form
Coalescer
Dryer
3. Moisture in Vapor Form (i nvisible).
Oryer
NOTE: A separator or a filler does not
remove moisture vapor
4. Conde'- 011 Particulate Filter
Separator
CoaiesceT Filter
Dryer
Carbon Adsorber
5. 011 In Aerosol or Mist Form
Coalescer
Oryer
8. 011 In V_ Form (Invilible)
Carbon Adsorber
Dryer
7. Particles (dirt , scale, etc.) Particulate Filter
Coalescer Filler
Bener choice(s).
TABLE 1
PIONEER AN tNNOVATIVE COMPANY 6
.,R,N
Q
"'<I<'aa.,C OR
-' .. . - . ': :.' .. .
. ,:.... . .' : .. ; '. '<'. -" ' . "
. .. . ... :' -"', :' ' .' " ". ', '; , ' ' ...
, , . .... : .... : :
' .- .... ..... .
-; - ' ..... . ..
. . '
..
.... __ '
.II10 ... 1OC
OR.' ..
O
.. '
P ,ICLU (O'Rl.
SCt.Lf' 0 1111:a)
PIO"UR
OLH}IIUC; .'" OA
OR
REOENERU'Vr ORUII I!'
. .
Component Functions
. . .

. UlO".nC

..
. .
. .
_,,''''Lr
. 1110... '1(;
o
..
",o .. ua
.nta"Ll{11 ,
FIGURE 1
I , Compressor -" Compresses atmospheric air into a useful and versatile utility. During
Ihe process, lubricanls are commonly added. If not removed. dirt , oil and moislure
will flow downstream causing maintenance problems, product rejects and costly
produClion shutdowns.
2. After Cooler - Condenses up to 70% of Ihe moisture.
3. Separator - Separates condensed liquids.
4. Automatic Drain Automatically drains condensate.
S. Receiver - Provides storage for compressed air.
6. Prefil ter - Improves performance, reliabilty and service life 01 the dryer
7. Dryer Condenses and removes moisture.
8. Cold Coalescer - Condenses and removes oil vapors al the most effective location.
9. Adsorber - Removes leftover traces of oil and water vapors,
10. Aft er Filter - Removes leftover particles.
11. AQUA SAVER - Closed loop water cooling system. Atso available with trim cooler
and process chiller.
COMPRESSED AIR SYSTEMS GUIDE 7
A Reliable
Compressed Air
System
Separators
Baffle Type
A separator with one or more baffles to cause change in direction of the air stream.
Baffle type separators are aO-90% efficient.
A I R 1 N ~
TQPVIEW
FIGURE 2
Cyclone Type
A separator that spins the air 10 throw 011 the free water. Cyclone type separators are
90-95% efficient.
- - - ~ __ ~ ~ ____ J'--
AIR IN ~ ..... AIR OUT
FIGURE 3
Centrifugal Type
Thei r 95% plus elficiency raling makes them the most efficienl1ype. They incorporate
barile, cyclone. impingement and centrifuge action. PIONEERCENTRt FLO
Separators (2" and larger) have a separate,condensate chamber which further i mproves
their efficiency 10 over 99%.
DPAlNTO
COOOENSATE
CHAMBER
SEPARATED
CONDENSATE
CHAMBER __
- - -- -- - - - - -
U-;F- AIR OUTLET
WHIRLEY BIRD
SIGHT GlASS
r(OTIONAl)
- --- - ~ MOISTURE DRAIN
PIONEER - AN INNOVATI VE COMPANY 8
FIGUAE4
Proper filtration is an essential part of a reliable compressed air system because:
1. Air logic. instruments and other plecision type air devices malfunction when dirt
and oil plug orifices.
2. Oil aerosols in compressed air cause uneven painting and increased product
rejection rate.
3. Oi l aerosols in compressed air coat sensing devices in Instruments and equip-
ment: causing malfunction and work stoppage.
4. Acidic contaminants in compressed air damage seals in cylinders, valves and
tools causing reduced production or shutdowns.
5. Contaminated air coming in contact with food, pharmaceutical or similar products
will cause rejection of Ihe complete production run.
6. Contaminated air will hinder performance of, and may damage your air
drying equipment .
Atmospheric Air
It contains millions 01 solid particles 01 dust and pollutants. It takes 7.8 cu. It. of atmos-
pheric air 10 produce 1.0 cu. II. of compressed air@ 100 PSIG. In other words, the con
centration of contaminants Is 7.8 times greater In compressed air as compared to
atmospheric air.
Compressor
The compressor lubricants become entrained in the compressed air. Additionally, higher
compression temperatures (up to 42S' F) vaporize and burn some lubricants. The result
is a hot, acidic, corrosive and abrasive mixture that must be removed.
Particulates
Particulates Quantity
.01 11m to 0.2J.1m
.2 J.lm to 1.0J.lm
.0 J.lm to 2.0 f.lm
2.0 11m to 10.0 )Im
0.0 J.lm and larger
Hydrocarbons
6 x 10
8
particleslft
3
3){ 10
7
partlcles/tt
3
1 ~ 10
5
particles/tt
3
10
Settle down
TABLE 2
Up to 10 PPM hydrocarbons are commonly present in industrial atmospheres. This ex-
plains why even non-lubricated compressors require liltration.
Moisture
Moisture Held by Air (at Dew POint )
Temperature PPM(Weight) Ounce 1000 ft.
3
150' F
120' F
100' F
80' F
60' F
40' F
32' F
-25' F
200,000
80,000
42,000
22,000
12.000
5, 100
3,200
200
287 oz.
1150z.
60 oz.
32 oz.
17 oz.
70z.
4.6 oz.
.3 oz.
TABLE3
COMPRESSED AIR SYSTEMS GUIDE 9
Filtration
Sources of Contaminants
Typical Industrial
Atmosphere Contaminants
Contaminant
Removal by
PIONEER Filters
Separator Plus Feature
Filters remove solid and/or liquid contaminants trom air or gas by one or more althe 101-
lowing methods:
Impact
Panicles 1.0 J.lm and larger coll ide and adhere to Ihe filter media.
IMPACT (1 .0 10 Ilffi) DI FFUSION (0.3 ~ m aOO smaller)
:
:
INTERCEPTION (0.3 - 1.Q).irnJ
GRAVITY (10 ~ m ardlargO:l)
FIGURE 5
Interception
Particles larger than Ihe filter media pores (0. 1 0.3 ).lrn) are removed by interception.
Diffusion
Particles 0.3 J.lffi and smaller are removed by diffusion. These smaller particles diffuse
from Ihe ai r/gas stream to the surface of the fi lter media.
Gravity
Coalescing makes smalter particles into larger particles which fall to the bottom 01 the fil-
ler due 10 gravity (10 J.lffi and larger).
ClEAN
GAS
EXITS
FIGURE 6
Larger PIONEER fil lers ate available wi th buitt-in centrifuge separators, designed for in-
creased elficiency and longer element life.
PIONEER - AN INNOVATIVE COMPANY 10
PIONEER Particulate Filters
Resin-bonded tiber elemen! and pleated design give these filters 10 to 20 limes the filter
area of coalescing Iillers. Therefore, these IiIlers have very low initial pressure drop (0.5
to 1.5 PSI) and an extremely large holding capacity. Partlculate fitlers will irlCrease the
uselullile of the coalescing fillers by up to 6 times while reducing the overaU system dif-
ferenUa! pressure during thai period.
Particulate filters are recommended for:
Prefillers lor coalescing fillers
After-fillers fOf regenerative dryers
Alief-fillers for deliquescent dryers and adsorbers
General purpose fitler for basic protection 01 air operated equipment , lools and
instruments.
PIONEER Coalescing Filters
Coalescing means to come together. II is a continuous process in which small aerosols
come in contact wl1h other small aerosols on the surface of the fi lter media. The collec
tion of aerosols form droplets that are large enough to be separated and drained by
gravitational force.
Coalescer Riter Media is resin impregnated for strength which prevents rupture due to
differential pressures as high as 40 PSIG. It has an enormous 90% plus void volume
which assures constant high efficiency and low initial pressure drops, ' .0 to 2.0 PSI at
maximum flow. PIONEER coalescing filters have 99.9% pius lubricant removal elficien
cy down to 0.3 fJm {based on D.O.P. test) and are effective in removing particles down
to .01 fJm.
PIONEER Micro-coalescers
For l iner coalescing PIONEER offers Micro-Coal escers. Their D.O.P. elllciency lor
0.010.06 ",m particles is 99.999'ro. A coalescer is recommended as a pro-lilter lor a
MlcroCoalescer.
Adsorbers
These lilters are carbon coated to remove traces of oi l.
A very thin layer of carbon, usually 1I8- to 1/4" adsorbs the oil: therefore, Ihese filters
have a very limited practical value. Moreover. replacement of elemenls Is easy to over-
look, because the pressure drop across an adsorber filter goes down not up, as in other
filters.
The PIONEER vessel l ype adsorbers charged with carbon usually have carbon depth in
feel. These are extremely effective in removing oil vapors, providing oil free air.
COMPRESSED AIR SYSTEMS GUIDE 11
Adsorbers
Deliquescent Dryers
Designed for 30'F to 70'F
PDP Suppression
PIONEER 'Super' design
has severa/advantages
over other deliquescent
dryers
To deliquesce means 10 mell away. A typical deliquescent dryer consists of a pressure
vessel holding deliquescent desiccant. The desiccant absorbs moisture and dissolves it -
self into a liquid state. In a typical deliquescent dryer the dew point 01 ai r is suppressed
or reduced by only 15-20' F.
PIONEER manufactures a
OUTLET
super deliquescent dryer
FtLlPORT
RELIEF
which is capable of up to 70' F /V"-VE
dew point suppression. II ;nvol
CONNECTION
ves lour slep drying: In step
one the air passes through the
separator section and drops MINIMUM
easily separated and free Ji -
DESICCANT
quids. The steps two and
LEVa
three involve drying by liquid
DESICCANT
absorber sections. The air
STEP 4
comes In contact with increas-
BED
DAY"""
ing concentrations of desic-
cant and water solution_ Step
four involves drying by solid TRAYS OF
desiccant
DEStCCANT
& WATER
As the solid desiccant in the MIXTURE
upper portion 01 the dryer be-
.., STEP3
comes a concentrated solution
I DRYING
il drips to Ihe trays below 10
STEP 2
form the liquid absorber sec-
DRYING
lion. The upper Iray overflows
into the tray below. A dilute
desiccant solution lalls to the
->.=.-",-:
STEP 1
bottom, from where it is
DAYING
drai ned periodically.
DRAIN
FIGURE 7
1. Minimum Desiccant Consumption
About half of the moisture is removed i n sleps 1, 2 and 3. Since they do not use any
new or additional desiccant, its usage per Lb. of water removal is aboul hall that used i n
compeli tive systems.
2. Trouble Free
Because the drain solution i s almost free of solids, the drain cloggi ng commonly as-
sociated with other deliquescent dryers is virtually eli minated.
3. Lowest Overall Cost
Minimum desiccant usage, no energy usage and Virtually no maintenance costs result i n
the lowest overall cost.
PIONEER - AN INNOVATIVE COMPANY 12
The warm, moist air enters the air to air heat exchanger, where it is precooled with out
going cool air. The cooling of air causes moisture condensation and minimizes heat ioad
on the refrigeration system. This condensate is removed (larger sizes), and air flows to
the ai r-ref rigerant heat exchanger.
Precool ing allows use of a smaller refrigeration unit and lowers the cost of drying. The
precooled air is further cooled to the 3S' F range in the air to refrigerant heat exchanger.
The cooling capacily is provided by the refrigeration system. The cooling 01 compressed
air causes condensation 01 moisture which is separated by a highly efficient centrifugal
separator. Condensed moIsture is drained automatically by an automatIC drain from the
separator.
The cold dry air flows through the air-to-air heat exchanger where it is re-heated by the
incoming warm air. Reheating increases the volume 01 air, prevents the sweating of air
lines and lowers the relative humidity of the air thus enabling it to do more work. The
clean. dry air is then available fOf use. (Heat Exchangers and Refrigeration Systems In
an ADA System are about twice the size of that of an A series dryer of equal capaci ty).
NOTES:
WET AIR IN
HOTREF IN
AOJ. TlI,eR
"""N

ADJUSiABlE TIMER

1. Typical temperatures in A series dryers.
DAAN
2. Typical temperalures in ADA series dryers.
3. Standard drain system in A100 (ADRSO) & up.
4. Wei Air Dry Air Freon
ADJ TI MER
DRAIN

AOJUSTABlETIMEA
ORAfNQ1
FtGURE 8
S. Standard in A3000 (ADR1500) & up: optional in smaller sizes.
COMPRESSED AIR SYSTEMS GUIDE 13
PIONEER
Refrigerant Dryers
Designed for 3S"F 10
SO"FPDP
Typical Flow Di agram
for PIONEER R &
ADRSyslems
PIONEER Triple Tube
Design [RIOO (ADR 50)
& Up]
U.S. Patent No. 4,638,852
PIONEER Offers Several
Types of Refrigerant Dryers
PIONEER TRIPLE TUBE DESIGN
U.S. PAT. NO. 4,638,852
FIGURE 9 FIGURE 10
PIONEER'S " TRIPLE TUBE" design subjeCls a thin laver of compressed air between
two cold surfaces.
Advantages:
1. Two oul ollhree lubes provide heat transfer surtace versus one oul of two in a
conventional heal exchanger.
2. Because the air is exposed to the cold surfaces from the lOp and the bottom, the
required tube lengths and therefore the pressure drop is reduced.
3. II provides a more compact heal exchanger and system design.
4. Because of shorter required tube lengths, l ube bends are eliminated. This further
reduces pressure drop.
5. Heallransfer sur1 aces are 01 copper to prevent rust and corrosion.
6. Optimum performance and maximum elficiency are achieved with plain tubes
and wi thout the disadvantages of the extended surface tubes which increase
pressure drop and foul lhe heat transfer surfaces.
7. Full six year warranty.
I. R-Series
Designed for use with an aflercooler, the R-Series design conditions (In accordance
with the NFPA and CAGI Standards) are: 100' F Inlet, 100 PSIG Inlet . 100"F Ambient,
maximum Pressure Drop of P$IG at raled flow and 3S"F range Pressure Dew Poinl.
2, ADR Series (After Combination System)
ADA systems are designed for compressed air systems which do nol have a previously
installed afl ercooler. They perform three functions - aftercooling. air drying and reheat-
ing of compressed ai r. These systems can take inlet air temperatures of up to 200' F.
3_ MR. GOOD AIRE System.
Available with R and ADR series. these systems include:
I . Prefilter with 6P Gauge. , ---- ---- - ---,
2. Cold Coalescer with AP Gauge.
3. TImer-operated drain valves complete with a
cleanable 'Y' Strainer and an isolation valve.
4. Three valve by-pass for the complete system.
5. Full live year compressor warranty.
6. Full six year heat exchanger warranty.
Advantages:
1. No Hassle.
2_ No Cost overruns.
3. Timely Instalialion.
4. Belter Duality Air- Tests prove that the
strategically located cold coalescer is 50 to
100% more effective.
MR. GOOD AIRE Plus (Oil Free Air)
FIGURE II
A coalescer Is designed 10 remove oil aerosols and not oil vapors. To remove oil vapors
and to provide the finest industrial and instrument quality oil free air PIONEER offers a
carbon adsorber and a particulate lilter installed after the cold coalescer. The particulate
filler prevents the carbon carry over.
PIONEER - AN INNOVATIVE COMPANY 14
Commonly used regenerative desiccants are sil ica gel, molecular sieve, activated
atumina or a suitable combination of these desiccants.
Silica Gel
Probably the most effecti ve desiccant when the relative humidity 01 the air stream ran
ges between 35 to 800/0.
Typical characteristics:
Silica (Si02): 99.7 1% by Wt.
Pore Sizes: 4 22 angstrom (t angstrom", 1 x 1O.
8
cm)
Surface Area: 750 800 Sq. meters/gram
Sp. Heat: 0.22 BTUlLbI' F
Apparent Butk Density: 45 LbSiCu. Ft.
In the presence 01 heavy moisture or liquid water. the desiccant is susceptible to frac,
tures. The breakup causes desiccant lines and excessive pressure drop. Therefore,
the desiccant is typically used with a predrylng bed of activated alumina.
The bead type silica gel (e.g. Sorbead) are spherical in shape and are less susceptible
to breakup. The bead type sitica gel is preferred when used alone.
Although pressure swing regeneration is often used, the thermal react ivation is more
common. Regeneration temperatures of 250' F to 500' F can produce dew poinls down
10 ,80T Si lica gel is often used for drying nalural gas.
Molecular Sieve
Probably the most effective desiccant when the relative humidi ty of the ai r stream is
below 35%. It is very effective in achieving low dew points down to 120' F. Molecular
sieve is ollen used for drying unsaturated hydrocarbons and other gases.
Typical characterist ics:
Molecular sieves are made of crystalline metal aluminosilicates (silica and alumina
tetrahedra).
Average Pore Size: 3 angstroms (1 angstroms = 1 x 10' 13 cm)
Sp. Heat: 0.23 BTU/Lb/ ' F
Apparent Bulk Density: 45 LbsiCu. Ft.
Disadvantages:
1. Higher regeneration temperatures 3SO' F to 700F.
2. High cost.
Activated Alumina
Overall . it is probably the finest all purpose desiccant. It is ideal for drying air and most
other gases at high relative humidity.
Advantages:
1. Allhough prolonged exposure to liquid water will damage activated alumina. it is
more resilient to water than silica gel or molecular sieve.
2. Low pressure drop due to its spherical shape.
3. High crush strength.
4. Less expensive.
5. l ow abrasion rate.
6. Long service life.
Typical characteristics:
Act ivated alumina is primarily aluminum oxide (AL<?03).
Pore sizes: 422 angstroms (1 angstroms ", 10-8 cm)
Sp. Heat: 0.22 BTUl Lbf" F
Apparent Bulk Density: 48 Lbs/Cu. Ft.
Pressure swing as well as thermal regeneration at2SO' F to 500"F are both commonly
used. With low inlet stream temperatures it can produce dew points down to ,I OOF.
COMPRESSED Al A SYSTEMS GUIDE 15
Regenerative
Desiccants
Types of Desiccants
Desiccant Service Life
Why More Desiccant?
PIONEER provides more
desiccant for several
reasons:
With repeated regenerat ion. typically desiccanl s are subject to a SLOW decl ine in their
useful dynamic capacity. The useful service life of desiccant is highly dependent on the
composition of air/gas to be dried and the dew pOint requirement. In drying clean air, a
service li fe 01 ten years is not uncommon. Factors that affect desiccant li fe are:
I . Therma Shock Constant heating and cooling causes fracturing and reduction of
pores and capillaries in desiccant Higher regeneration temperatures produce
greater thermal shock.
2. Foul ing of pores and capillaries from dirt. dust and hydrocarbons.
HJIn. ... lJ'.'AOSOAI'TlONc;.\I'AClTII!.Sor- ,,",SOCtN<'S


1..- _
r---- YEIlYEfF'CTIVE
SLICAGE:,:>:-
/
VOI. ECULAiI
/' v---- \ S'EIII:
/
1/ : /'
:;-
,
:

CT"' ATfO
AU"""""
-
' X
-
,-
....... I ...
FIGURE 12
A typical PIONEER dryer is supplied with premium quality, high-crush strength (70
lbs.), low-abrasion loss (l ess than 0.1% Wt.) type, U.S. made activated alumina. Most
competitors use less costfy, foreign made alumina. PfONEERsupplies more desiccant
in their products than the competition.
Example: To dry 1000 SCFM of 100' F, 100 PSIG. saturated air to 40"F PDP with
an external heater type dryer (PIONEER Model PHE 1000).
Pounds of water to be removed in a four hour (wH20l Cycle =
(18.016) (t)
Where,
F;
387
p.
P
Saturated or wet air flow in SCFM
SCFM per lb. mole
Vapor pressure in PSrA@ inlet conditions
Minimum drying pressure in PS1A
Drying time in minutes
Molecutar weight of water (lbllb mote)
t
18.016
w
H
2<l
= (tOOO ) ( 0.94959 ) (18.016) (240) = 92.5 l bs.
387 114.7
To remove 92.5lbs. 01 water, PIONEER provides 800 lbs. 01 desiccant per tower-
more than its competi tors.
Comparison
PIONEER(PHE 1000)
Brand X
Lbs. of % Dynamic
Desiccant Tower Adsorption CapacIty
800 lbs.
580 lbs.
92.5/800 "' 12%
92.51580 '" 16%
TASLE4
1. Dynamic adsorption capacity 01 desiccant decreases with use.
2. The adsorption process gives off heat. reducing the relatfve humidity 01 the air.
and decreasing the adsorption capacity of the desiccant.
3. Slight changes in operating conditions can have a severe effect on dryer perlor
mance.
4. More desiccant usually requi res larger diameter vessels. larger diameter vessels
procluce lower air velocities typically less than 40 F.P.M. The lower air velocities
produce minimum desiccant attrition, more contact time (up to 10 sees) and more
consistent and lower dew point.
PIONEER AN INNOVATIVE COMPANY 16
A typical Regenerative Dryer consists of two towers charged with activated alumina
desiccant. One tower dries air while the desiccant in the other tower is being
regenerated with low pressure and low humidity air. Often heat Is added to assist the
regeneration process.
Heatless Regenerative Dryers (PIONEER PHL Series)
In this design, a small amount of the dried air (from the drying tower) is expanded to
near atmospheric pressure in the regenerating tower. The dry air becomes super dry on
expansion and readily absorbs the moisture from the saturated desiccant bed.
PHl Series offers maximum in reliability. A solid state timer and valves COfltrolthe entire
drying and regeneration process.
A typical 40' F PDP system uses a ten minute cycle: five minutes drying, 4.5 minutes
regeneration and 30 seconds repressurizalion.
Due to their low initial cost and low maintenance cost. PHL dryers are generally used
whenever sufficient compressed air capacity Is avai lable. They purge approximately
t4"1 .
External Heater Type Regenerative Dryers
(PIONEER PHE Series)
The PIONEER PHE series is equipped wi th an external electric or steam (optional )
heater to raise the temperature of purge air. The higher the temperature, the greater the
capaci ty of air to absorb moisture, thus heating of the purge air reduces the volume 01
dry air required lor regeneration.
The heater element does not come in contact with the desiccant, thereby the heater
tube prevents physical deterioration olthe desiccant material.
PHE dryers mostly retain the simpliclly of PHL dryers and yet cut the purge air require,
menllo 3 10 6%, depending upon the regeneration temperature. This feature makes
them particularly suitable for install ations where not enough excess compressor
capacity is avail able for PHL dryers.
Blower Purge-Zero Purge (PIONEER PHEB Series)
External heater type dryers easily lend themselves to the use of an external blower to
supply purge air. Because purge air is needed at near atmospheric pressure, use of a
blower for purging is ideal. especially in targer drying systems. Their disadvantage Is the
fluctuating dewpoint.
Internal Heater Type (PIONEER PHI Series)
In these dryers the purge air heaters are install ed inside the desiccant chambers wi thin
protective tubes to avoid contact with desiccant. Besides heati ng the purge air, heaters
heat the desiccant because of thei r location. This helps evaporate moisture fr om the
desiccant and reduce the purge ai r requirement to approximately 3%. Their dlsad,
vantages are higher regeneration temperatures and uneven heating of the desiccant.
Hybrid Drying System (PIONEER FUTURE-AIRE)
FUTURE-AIRE combines the advantages of a refrigerant dryer and a regenerative
dryer. A PIONEER Refrigerant Dryer is used to lower the pressure dew poinl (PDP) of
compressed air or gas 10 35"F to 40' F and a PIONEER Heatless Regenerative Dryer Is
used to lower the pressure dew point (PDP) to -4Q"F to IOO' F.
The moisture content of saturated air@ 100 PSfG is:
At 100' F PDP: 0.603 Oz/I00 SCFM
At 40' F PDP: 0.077 oz/ l00 SCFM
The moisture content of the air @ 40' F PDP is less than 13% of the moisture content 01
air@ 100' F PDP. The FUTURE AIRE System lakes advantage of this facl. Because
the relrigerant dryer removes 87% 01 the moisture, the purge air requirement by the
regenerative dryer is only a fraction. PIONEER design of this hybrid system further
reduces the purge air requirement by heating the purge air to t SO' F with the normally
wasted condenser heat of the refrigerant dryer. The net purge air requirement is:
For -40'F: 2% approximately
For 100F: 3% approximately
These are Ihe most elficient and reliable regenerative dryers.
COMPRESSED AIR SYSTEMS GUIDE 17
Regenerative
Dryers
A Comparison of
Regenerative
Dryers
Cost Comparison
Average Vearly Tolal
Relrrg Operating Yearly Yearly
Capacity
"
COSlof Cosiol Yearly Cost
Dryer
"
Healer KW Relng Purge EquIp Sum 01 Overall
Type SCFM Usage or Healer Air Loss Cost .. Cost
FUTURE-AIRE 100 0.4 $ 210

263 $ 945 $ 1418 lowest
(HOS) SOO 2.0 1051 1314 1973 4336 Lowest
1000 4.0 2102 2626 3289 801'
Lowest
2000 8.0 4205 5256 5068 14529 Lowest
H .. _
100

S 1840 S 55. $ 2399 Highest
(PHL) 520
"98
1022 10220 Highest
1000

18396 1750 20146 Higheal
2000

36792 2660 39452 Hlghaat
External 100 1.0 $ 526

526 $ 811 $ 1863 Medium
Healer SOO 5.0 2630 2630 , 393 6653 Medium
(PHE) 1000 10.0 5260 5260 1750 12270 Medium
2000 20.0 10520 10520 2660 23700 Medium
Internal 100 1.0 S' ... S 394 $1106 S 2026
Heal8< 500 ' .0 2630 1970 1750 6360 Medium
(PHI) 1000 10.0 5260 3940 2730 11900 Medium
2000 20.' 10520 7880 4130 22530 MedIum
TABLE 5
Assumptions:
1. Cost of compressed air - $0.25/1 000 SCF
2. Average KW usage by a refrigeration system of a FUTUREAIRE System - 0.40
KW/1 00 SCFM.
3. Average KW usage by a heater in a heat reactivated dryer - 1 KW/1oo SCFM.
4. The dryer is operating 8760 HrsJYear.
5. The equipment is depreciated over five years.
6. Energy cost is $O.06JKW.
7. All amounts are rounded 10 nearesl donar amount.
Sample Calculations:
1. Yearly operating cost of a refrigeration unit for a HOS 500 Dryer.
= Avg. KW Usage I Hours. Energy Cost
{SOO .IMQ ) l8760. 0.06 $1 051.20lYear
\ 100
2. Yearly operating cost of a heater for a PHE 500 Dryer.
'" Avg. KW Usage I Hours I Energy Cost
roo x t& ) x 8760 x 0.06 = $2628.0OJYear
3. Yearly operating cost of purge air loss for a HOS 500 Dryer.
= Purge l oss in SCFM x 60 x Hours x Cost of Air per SCF
{SOO x.l.2 ) x 60 I 8760 x $1314.00
\ 100 1000
4. Equipment Cost.
The average pri ce of a HOS 500 unit sold is $9863.00. With a five-year deprecia-
tion the cost per year is $1972.60.
PIONEER - AN INNOVATIVE COMPANY 18
lower .
-
- -- Medium - - H1gher
1.lnillal Cost HeaUess(PHl) Elf!. Healer(pHE) Inl. Healer (PHI)
Blower Purge (PHEB)
FutureAlre (HOS)
2. Oper.llng Cost Future-Air. Blower Purge Int Heater
"..""'"
Ext Heater
3. Overall Cost Future-Alre Blower Purge Inl. Healer HeaUess
Ext. Heater
4. Pur .. Requirement Blow.r PUrge Futur.AJr. Int. Heatet Ext. Heater He .....
S. Maintenance Future-Alre Hea!less Ext. Healer In!. Heater
Blower Purge
6. EquIpment Uf. Int. Healer Ext. Heater- Futu,.AJre
Blower Purge Heatless
7. Reliabi lity Inl. Heater Ext. Heater Future-Air.
Blower Purge Healktss
8. Dew Polnt PerforlNnce Blower Purge Hea'", Future.AI,.
Int. Heater
81t. Hearer
TABlE6
This oplionaJ feature available in heaUess as well as heat reaClivated dryers ensures
that the dryer will use the minimum of air/gas fOf regeneration. minimum of air/gas for
repressurizalion and minimum heater usage (i n heat react ivated dryers) for regenerat ion.
In systems with Demand Cycl e Control, a humidity sensor monitors the dew point of the
filtered outgOing air/gas. When the dew point of outgoing air reaches Ihe preset point.
the drying and regenerating towers shltl Iheir roles. In other words, with Demand Cycle
Control the frequency of tower switChing, and therefore the amount of energy needed
for regeneration, is In proportion to Ihe air usage.
This makes Demand Cycle Control a useful tool for saving energy In applications
with fluctuati ng air demand.
Comparison
t. FUTURE-AIRE saves on energy costs all the time.
2. Demand Cycle ContrOl makes regeneraling costs proportional to the air usage in-
stead of being fi)(ed to Ihe ma)(imum flow Ihrough the dryer. The Demand Cycle
Control saves when the air usage is tess than the mal<imum, however, it
does not save when t he air usage is at or near maximum. Therefore, the
demand cycle does nol reduce the needed compressor capacity.
3. In practice, the FUTURE-AIRE over regenerates the desiccant whereas the
Demand Cycle Conlrol regenerates the desiccant to lust necessary level. There-
fore, the FUTURE-AI RE delivers lower and more consistent dew point
(-60' F is common). Because the desiccant is over regenerated in a FUTURE
AIRE System, the problems of residual moisture and desiccant decay is mini-
mized, and the desiccant life is increased.
4. FUTURE-AIRE is more rugged and reliable than available humidity
sensors.
Overall, FUTURE-AIRE is more reliable, belter performIng and more economical.
COMPRESSED Al A SYSTEMS GUIDE 19
Overall Comparison
Demand Cycle
Control
Demand Cycle vs.
FUTURE-AIRE
Air Dryer Selection
Table
Water Cooling
Systems
Oe-'>lted Rl'j"ge,am
Press",,, & O .. l1qu""cp,,1
Dew Po,nt Apphc,ll'OO Regrneral'v<' Aeh'9,,'aled Comb.naMn fUTUflE AIRE
SO" General Plant
air for \ools.
cylinders. valves, YES
-YES - YES YES YES
etc. , ambient
over G5"'F
35" Genera/ planl
air lor tocQ.
-,-,

YES -YES -YES YES YES
_ ... air

wtwnambieN
,,-""
0" General p!ant
air tor tools,
cylinoers, valves.
Instruments, YES
controls, gauges.
-YES - YES
cllemical processing.
when ambient
is over t 20'F
...,'.
-
rtquJring
. -YES
and/or sub ZlfO
eondltlons
.so"
requlllnO
except ionally
YES - YES
dry air andlor
ambients down
10 -40'F
Belter Choice(s)
TABLE 7
City Water Cooling
Disadvantages:
1. High cost of water.
2. Sewage cost.
3. UnCOn!rolled water lemperalUre.
4. Scaling problems.
5. Possible government restrictions.
The use 01 ci ty water for a trim cooler in conjunclion with a closed-loop cooling system is
economical because the city water is generally needed only during the day in summer
months. The rest 01 the time, the atmosphere is usually cool enough to coollhe water.
The average city water usage is only about 2%.
Evaporative Cooling
1. Typically, 15% of the cool ing water is lost resulting in high water and sewage
costs.
2. Algae and scaling problems.
3. Water treatment costs.
4. Required sump water heating in winter.
5. High maintenance and cleaning costs.
PIONEER AN INNOVATIVE COMPANY 20
Closed-Loop Cooling (AQUA SAVERS)
Free atmospheric air is used as the cooling media, These systems are virtually main-
tenance free with the lowest overall cost. The only limitation Is that by ilself it can
only cool water \0 within 10 IsoF over the ambienllemperalures.
PJONEERoffers two options thai overcome this limit ation and make closed-loop cool ing
systems the ideal choice for cool ing air compressors and other industrial equipment.
1. Trim Cooler
These heal exchangers provide supplemental cooling using city water as a cooling
medium and are ideal for providing 85 - 9S' F water.
Advantages:
1. Allows you to select a smaller AQUA SAVER.
2. Provides desired temperature.
3. Minimizes water costs because the city waler Is used only on hot days for a lew
hours when the ambient temperature is too high. The average city water usage is
only about 2%. and lor most 01 the year, there is no water cost.
4. Minimizes sewer cost.
5. Minimizes maintenance because it does nOI have the problems commonly as-
socialed with evaporation-type cooling systems (caused by evaporation of water).
2. Refrigerant Cooling
In conjunction with a closed loop cooling system this is an economical and reliable way
to provide cooling waler at temperatures below as' F. The cost of cooling is low because
the refrigeration cooling is generally needed only during the day and in summer months.
PIONEER oilers pre-piped and pre-wired combination cooling systems with both options.
The additional benelit of AQUA SAVERS is thai they lend themselves to heal recovery.
Heat Recovery
AIR INTAKE
(in summer)
AIR INTAKE
(in winter)
AQUA
SAYE!!.
_I
Exchanger
THERMOSTATICAlLY-
CONTROLLED
LOUVERS(4)
AIR DISCHARGE
(in winler)
AIR DISCHARGE
(in summer)

FIGURE 13
COMPRESSED AIR SYSTEMS GUIDE 21
Compressed Air
Data
Instrument Quality Air
Requirements: In accordance with the Instrument Society of Ameri ca standards
(ANSI/ISA . 57.3 1975) (RI981 ) are:
1. Maximum Particle Si ze - 3 micron
2. Oil content - 1 PPM w/w or vlv or less under normal operating condi tions.
3. Pressure Oew Point - At leasll 0' C or 18"F below the lowest ambient
temperature.
4. Air shall be free of aU corrosive contaminants and hazardous substances.
How To Estimate Compressed Air Capacity
Generally, the compressed air capacity of an air compressor is rel ated 10 its horsepower
(HPJ. A good rule of thumb is:
DISCHARGE PRESSURE (PSIG) SCFM CAPACITY HP
Example:
75
100
125
150
6.0
5.0
4 .5
4 .0
TABLE S
The typical capacity of a 100.0 HP compressor at 100 P$IG is 5 x 100 - 500 SCFM.
Air Discharge in SCFM Through
An Orifice to Atmosphere
Air Pressure Before Orifice Diameter 1l.!:!l!!..che.M
Onflce (PSIG) 164 132 116 18 14
"
12 58
1 .028 0.112 0.450 1.80 7. 18 16.2 28.7 45.0
2 ... 0 0.158 0.633 2.53 10. 1
22.'
40.S 63.3
,
... , 0. 194 0.775 3.10 12.4 27.8 49.5 77. S
,
.056 0.223 0.892 ' .56 14.3 32. 1 57.0 89.2
5 .062 0.248 0.993 3.97 15.9 35.7 63.5
99.'

.018 0.212 1.,
.'"
11 .
""
.. ~ 109
,
.' 73 .203 1, 17 ...
,.,
m ,>.0 117

.083 0.331 1.32 .30 21.1 U .l ... ,
132
12 ....
.. ,.
1.52 8.07 ...
50.' 97.0 152
15 . 1OS .. 20
'"
' .n
2 ... " .5 108 188
20 .123 0.491 1.96
' .as
31.4 70.7 126 196
25 . 140 0.562
'"
8.98 35.9 80.9
'"
225
30 .1 58 0.633 2.53 10. 1 40. 5 91.1 162 253
35 .176 0.703 2.81 11 .3 45.0 101 180 281
"
.1 94 0.774 3.10 12.4 49.6 11 2 198 310
"
21 1 0 ....
.,.38 13.5 54.1 122
21'
338
50 .229 0.91'
, ... ,-V !S. 132
'"
'"
.. ".. 1.'" ' .23 16.9
,,.
152 271
82'
70 .300 1.20 ' .79
1,.
",
m 30'
".
OJ .33S 1."
."
21". ... , 10!
'" '"
90 .370 \.48 5.92
23.'
.... ,
213
'79
592
'00
.. '"
1.62 6.49 " .0
'"
2" '15 ...
110 . 441 1.76 7.05 28.2
'13
254 ' 52 '05
120 .476 1.91 7.62 30.5 122
'"
.. ,
'62
125 ....
1. " '.90 31.6
,,.
2" 506 790
NOTE:
----
34 7. 1
6'-'
88.1
'"
91.2 12< 162
11 1 152 198
128 175
".
'"
195
2"
'"
21'
218
, ..
230 300
,., ,..
339
21'
,.,
388
'"
""
.,.
283 385 SO,
'" '"
575
365 ' 96
'" " 5
551 no
" 6 607 ' 93
."
'"
865
'26
711 938
009
.,.
1,082
690 ... 1,22'
m 1."" 1371
'53
1,161 1.516
."
1.272 1,661
1,016 1.383 1.806
1,097 1.494 1,951
1, 138 1.549 2.023
TABLE 9
Above figures are based on 1 00% coetficl ent of flow. For a nonsmoolh orif ice, air discharge may
be only 50% ot above figures.
PIONEER - AN INNOVATIVE COMPANY 22
Cost Of Air Leaks To Atmosphere At 100 PSIG
Assumptions;
1. Cosl of compressed air $0.2511000 SCFM
2. 24 hour/day operation 50 wkslyear
EOUI VALENT
ORIFI CE SIZE COST YEAR
NOTE:
1/32
1116
118
"' 3/8
$ 204.12
817.74
3,276.00
13,104.00
29,484.00
TABLE 10
Above figures show that a good compressed air treatment system pays lor lIse!! in a short time.
Freon Pressure - Temperature Relationship
Temperature F Temperal ure F
Pressure Freon Ref!!AE'lanl Type Pressure Freon Refrigerant Type
PSIG 12
"
'02
PSIG 12
"
'02
0 22
."
50 60
"
"
26
,
."
39
.. ,
" "
J5 28
,
."
-36
.. ,
"
65
"
29
, .,. .,.
."
66
"
J8 30
,
." ."
.. 0
" "
40 J2
, .,
... ...
" "
"
J3

.,
...
.,.
"
"

"
,
..
."
... .. n
"
..

.,
."
.. ..
" "
<3

.,.
... .. ..
"
..
'0
,
." ."
" "
56
"
"
,
." ."
' 00 90
" "
"
,
."
25
'OS
" " "
"
,
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22 ,OS
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71
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83
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85 n
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SO
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.. .. 1
., ,,.
,r.;
"
83
" "

.. 115
'"
.. ..
27 ..

..
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,,.
..
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,
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, .. ,,.
.. ..
" "

. , , ..
".
"
e,
JO
"
, .,
'"
OJ. ' 00
"
" "
, ,
200
'"
'GO 95
,.
" "
,
'" '"
' OS
..
J6 39
"
,
'"
'"
'"
'GO
J8
" "
,
230
'" '"
, ..
.. ..
"

."
,,.
'"
' Of
.. ..
,.
"
250
,,.
'" '"

" " "
...
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, ..
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..
. ,
23
'"
Z10
, ..
,.,
'Of
..
"
.,.
"
...
.
'"
'" 50
"
,.
"
290
'" '"
52 55 28
"
JOO OJ,
'"
"
57
" "
" " " "
58 60 J2
"
TABLE 11
COMPRESSED AIR SYSTEMS GUIDE 23
Moisture Content of Air In Grains/Cu.Ft. at Various
Temperatures and Relative Humi dity
QoSaluration
"--'-0- 30- 40-- - 50 60--7-0-- "
99 100
Temperature ( F)
- ----Weight 01 V/ater Vapor (gralnS) --
"
0.028 0.057 0.086 0. 114 0.142 0.171 0.200 0228 0.256 0.285
0 0.048 0.096 0. 144 0.192 0.240 0289 0.337 0.385 0.433 0.48.
10 0.078 0. 155 0233 0.210 0.388 0.466 0.543 0.621 0.698 0.116
20 0.124 0.247 0.370 0.494 0.618 0.741 0 ..... 0.988 1.112 '.235
30 0. 194 0.387 0.580 0.114
0'" 1.16' 1.354 1.548 1.742 1.935
"
0.211 CA22 0 .... 0.8<5 .....
..,,.
1.419 1.690
"'0'
1.1'3
,.
0.237 0.473 0.710 0.947 1.113 1.'20 1.656 1.893 2.120
' .366
.. 0.285 0.570 0.'" 1.140 1.424 1.109 ..... 2.27i 2 .... 2.74i
.. 0.34' 0 .... ' .02< ,""
\ .701 2.(148 2.390 2.731 3.073 3.41
50 0.""
0.815 ,.223
.. ..,
2 .... 2.448 2.853 3.261 3.668 4.078
55 0.485 0.970 1.455 1.940 2.424 2.909 3.394 3.879 4.'" 4.849
60 0.574 1.1 49 1.724 2.298 2.872 3.447 4.022 4.596 5. 170 5.745
62 0.6'4 1.228
"'''3
2.457 3.071 3.685 4.299 4.91 4 5.528 6.142
"
0.656 1.313 1.969 2.625 3.282 3.938 4.594 5.250 5.907
' .563
"
0.701 1.402 2. 103 2.804 3.504 4.205 ..,0. S.S07 6.208 7.009
.. 0.7.a
, ....
..... 2.992 a .7.o ..... .236 5.974 7.712 7 ....
70 0.""
.. ... 2.394 3. 192 3.'" 5.788 S..,
'.384 7.182 7.'"
72 0.8051 1.702 2.562 3 . ~
..... 5. 105 5.956 ..... 7.M7
...,.
"
0.907 1.113 2.720
3."" ' .553
5_ ..... 7.523 8 . 159 . oea
76 0._ Ull31 ..... , ...
... 2. 5.703 fl.758 7.724 8.1190 .....
"
1.028 2.055 3.083 4. 1 I I 5.138 6. 166 7. 194 8.222 9.249 10.277
80 1.093 2. 187 3.280 4.374 5. 467 6.560 7.654 8.747 9.841 10.934
82 1.163 2.325 3.488 4.650 5.813 6.978 8. 138 9.301 10.453 11.626
.. 1.236 2.471 3.707 4.942 6.178 7.414 8.849 9.885 11.120 12.356
.. 1.313 2.625 3.938 5215 6.564 7.877 9. 189 10.S02 11.814 13. 127
..
, ....
2. 717 4. 181 5.575 . ....
' .382
'576 11 . 150 ,2.543 13.937
"
1.479 2 .... 4.437 5.916 7.395 8.874 10.353 11.832 13.311 14.790
92 ! .!le9 3.138 4.707 7.27. 7.844 9,413 10.982 12.561 13. 120 ,. ...
.. ' .663
... '
..... .... &.317
' .800
11.544 13.307 14.971 16.634
.. 1.183 3.525
,,..
7.050 8.813 10.518 12.338 14. 101 15.863 11.828
sa 1.867 3.'" 5.801 7.468 '.336 11 .203 13.010 14.937 16.804 18.671
' 00 1.977 3.953 5.930 7.906 '.883 11.860 13.836 15.813 17.789 19.766
TABLE12
Free Flow (or Volume) vs. Flow (or Volume) at
Pressure Conversion
a .. a 100
10 0.6 125
20 0.42
'50
30 0.33
'75
40 0.27 200
50 250
60 300
70 0.17 400
'"
0.16 500
90 0.14
FormUl a:
Flow or volume@ 'p' PSIG= ( 14.7 ) ~ free flow
p + 14.7
PIONEER AN INNOVATIVE COMPANY 24
0 . 13
0.11
0.09
0.08
0.07
0 .04
0.03
Moisture Content at Various Conditions
Ii
c
z
,
r
0
s
w
" a


'w w.
w
,

.-


w
0
<
;;
0"



.0 0 0
.>
w w
0,
"

w<
, ,
00
.;;
"

< <

'.


zw
00 w w
w'


", 'w


w w
wO
.> o.
<.>
,
FIGURE 14

At saturated conditions
2 3S' F dew point@ 100 PsrG Is equiva!enl to 10'F dew point@ATM. pressureor+7' Fdew polnt
@20 PSIG; However. only the pressure dew point altha line pressure is important.
COMPRESSED AIR SYSTEMS GUIDE 25
Useful Technical
Data
Heat Load (0)
FlUi d Formula
Water
0,'
50% E.G.
Air
I For Water 1.0.
a .. 500. GPM. SP. HEAT'
0", 210. GPM. 4T. SP. HEAT
Q .. 450 . GPM I.\T. SP. HEAT
Q E 1.08. SCFM .6T. SP. HEAr
____________________
Overall Heat Transfer Coefficient (U)
TUBE SIDE 50"0
FLUID WATER Oil E.G. AIR
Water
0 "
500/. E.G.
400
30
100 350 20
90 300
__________ __________________ -, TABLE 15
Conversion Data
1 PSI .. 2. 036 In. OF MERCURY .. 2.13 FI. OF WATER
.. 0.069 BAR .. . 070 KG/cm
2
" 6895 PASCAL
1 Cu. Ft. .. 7.48 U.S. GALLONS ,. 0.0283 Cu. METEA '"' 28.32 UTER
_ 29.92 QUARTS .. 59.84 PINTS ", 6.233 Imp. Gals.
1 FI.
, Lb.
_ 0.3048 METERS
.. 0.4536 KG .. 7000 GRAINS
1 U.S. Gallon 01 Waler .. 8.34 Los.
1 Cu. Fl. 01 Water .. 62. 4 Lbs.
1 Cu. FI. 01 Air .. . 076 Lbs. (Std. Pres. and Temp.)
1 CU. FI. 01 Natural Gas .. 1000 BTU (Approx..)
1Cu.F!. _ 7.48 Gals.
1 Liter .. 1000 Grams
1 Cu. Meier ,, 1000 Uters
1 HP _ 746 WATTS .2547 8TU/HR. 33,000 Ft. LbsJMin .
10.68 K.CALORIESlMin.
ASS, TEMP. oK _ 'C + 273
ASS, TEMP. ' R. ' F + 460
' F _ 32 + 1.8. ' C
1 BTU raises 1 Lb. 01 waler l ' F
1 BTU raises 54 Cu. Fl . of air I F.
1 Lb, of sleam raises 1 Gal . walef appmx. lOOT
Maximum Recommended Air Flow in SCFM Through
Standard Pipes @ 85 - 115 PSIG
5 075 1" 125" 15 2.0 25" 3 0" -l0" 50' 6
40 100 150 200 250 600 900 1500 2500 3500
Maximum Recommended Water Flow in GPM
Through Standard Pipes @ 25 - 50 PSIG
125" 15" 20" 25' 0" 60" 60'
36 50 78 450 600 1200
PI ONEER - AN INNOVATI VE COMPANY 26
Approx. Equiv. Length of Sch. 40 Pipe in Feet with
Same Pressure Drop as a Typical Fitting or Valve
NOM
PIPE SWING 90 90
SIZE GLOBE GATE CHECK STO WELDING ELBOW
INS VALVE VALVE VALVE ELBOW TEE TEE SHORT LONG

"
I 7 1.5 1.0 ' .1 -
-

23 I 9 2.0 1.5 ' .2 -
,
30 ..
"
2.6 I., 5.2 -
-
1/ ' 12
"
1.8
"
' .0 2.7
,
2.0 I.,
2 59 2.' 23 5.0 ' .5 10.5 ' .0
"
2" /2
"
2.7 28 '2
,.,
12.4
"
2.6
,
2
"
35 7.' 5.2 15.4
"
' .2
,
2 ' .5
"
10.0 6.' 20.0 5.5
,.,
5 2 5.6
"
12. 5 8.5 25.0 6.7 5 .
6 2 6.' Ii! 15.0 10.0 30 . 8. 6.'
,
2 9.0
'"
20.0 13.0 .... 0 11.0 8 .
NOTES: <D A typical swing check valve requires 1/2 PStG to open.
I>' Too much pressure drop for most applications.
TABLE 18
NEMA Enclosures
Type Type
1 General Purpose (lndoof)
2
3 Ousnighl , Rllinl>ghl , Sleet tighl (Outdoor,
JA Rail'lpfool , Sleet Aesi5lanl(0u1doOf)
3S Ousnighl , Rainligtll. SleelproollOuIdoor,
4 Walenighl , Dustlighl , C<lnosion A&sIsIanl
llndoo< or Ouldoof)
4X Walertighl , Ousttighl. COflosion ResiSlailt
(Indoor or 0u1dOOf)
5 Ousnighl . Indoo<
6 Submersible, Wat!fti9hl. Ousl!lghl. Sleet
Resistant (lndoOf Of o,ddOOf)
Formulas
1. VoIlS Amps . Ohms
2.
'"
3. l pBaseKw ..
'000
4. 3--pltase Kw .. ..... V_oIIS ...
'000
Motor Full Load
Amps (Approx.)
SINGLE PHASE MOTORS
HP 115V 2JOV
'"
' .2 2. '
'"
56 2.'
'"
7. 2 ' .6

9.' ' .9
.. 13.6
6'
,
"
7.'
1-1/2 20
,.
2
"
12
,
" "
,
"
28
TABLE 21
7 Class I, Group A, B. C or D Hazardous
locallOOS. Air-Bra .. (Indoor)
8 Class I. Group A, B. C or 0 Hazardous
Local ions, OiI l lTVIlIIf sad (Indoor)
9 Class II , Group E, For G Hazardous
Locations, Air Break (Irdoor)
10 Mirl9S
11 Cor ros!On Resislanland Dfipprool,
OiIlmmersed (Indoor)
12 IndUSlrial use, Dust1ighl and Oriplighl
( Indoof)
13 Oihighl and Dustlighl (Indoor)
5, Torque (UlJFI.) - I:I e.. .. 52SD
RPM
6. Pump HP _
3960, Pump Efllciency
TABLE 19
7. Fan/Blower HP .. CEM...ete.ssu(c,in..e.sJ.G
33000, Eiliciency
TABLE 20
THREE PHASE MOTORS
HP 200V 230V 460V 575V
,.
2.' 2
, .,
..
" "
,-' u
,
"
' .6
I.' I.'
' If.! 6 5.2 2.6 2.'
2 7.8 6.'
,.,
2.7
,
"
9.6
.. , ,.,
,
"
"
7.5
,
7 \f.! 25 22
"
9
,.
"
28
" "
" " " " "
20 62
"
27 22
25 78
" "
27
,.
92 eo
,.
"
,.
'20
''''
52
"
" '"
13"
65 52
60 In
'"
77 62
75 22'
'"
96 77
' 00 285 2"
'"
'''''
AM,,","P
LARGER SIZES
2.' 2.' 1.2 I..
TABLE 22
COMPRESSED AIR SYSTEMS GUIDE 27
Useful Electrical
Information
CDNFIDENCE
DVER 6D,DDD SYSTEMS INSTALLED.
CHOSEN BY NEARLY EVERY FDRTUNE
saD CDMPANY IN AMERICA.
VAALER
AWARD
TOP HONORS
-
f'IOHEfIl AlII srsnMS, INC.
----.-_ .... ' ---
-----''''_ ..
... "'-? .--
---
---