Stellantis PF.90088 Performance Specification - Air Intake Systems - High Pressure Piping Assemblies

Published by Stellantis, the multinational automotive manufacturing company formed by the merger of Italian-American Fiat Chrysler Automobiles and the French PSA Group "Stellantis standard PF.90088 “Performance specification - Air induction systems - High-pressure pipe assemblies” describes the environmental, physical, electrical, mechanical, functional, regulatory and durability requirements for high-pressure pipe assemblies within the scope of Air Induction Systems.

The purpose of the high-pressure piping system is to provide a reliable, leak-free method for transferring hot compressed air from the charge system to the charge air cooler and return air cooler, and to the engine. The peak air temperature distribution is provided in the table provided in the standard. The system must also prevent oil leakage from the hose.

This system has two groups of high pressure pipes:

• The hot side pipes allow the charge air to flow from the air compressor on the engine to the charge air cooler.
• The cold side pipes allow charged air to flow from the charge air cooler back into the engine and be fed to the engine cylinders.

According to the use, pressures, temperatures of the driven fluid and ambient radiation and hoses, they are subdivided and classified according to their types as shown in the tables titled “Hose types” and “pressures” given in the standard:

Classification is based on the combination of operating temperatures and pressures. For example, Type A/2 represents the average:

• A = pipelines with a continuous temperature of 150 degrees and a possible peak temperature of 160 degrees
• 2 = pipelines with a continuous pressure of 1,8 bar and a possible peak pressure of 2,1 bar

If class is not specified, Class 1 is assumed.

Since silicone compound (Type B) can cause oil sweating on the outer surface, a layer of fluoroelastomer or fluorosilicone, adhesively bonded to the inner channel, is required to ensure excellent permeability if necessary. In this case, the grade to be used is B-0.

The pressures stated should be considered as relative pressures.

If there is a pressure or temperature parameter lower than those reported in the tables (including tolerances), it is necessary to move to the next class.

The composite material must meet Stellantis MS.90058 standard.

The Stellantis PF.90088 standard is considered particularly important in industries where high-pressure systems are critical, such as oil and gas, petrochemical, aviation, power generation, and hydraulic systems. This standard is considered important for the following reasons:

• Ensures safety: High-pressure piping assemblies operate under extreme conditions. This standard provides specifications that help prevent failures such as leaks, bursts, or fatigue cracks that could otherwise cause injuries, environmental hazards, or catastrophic system failures.
• Standardizes quality and design: This standard likely defines minimum material specifications, construction methods, testing procedures, and design tolerances to ensure that all piping assemblies:
  • Consistent in performance
  • Meets industry-accepted quality levels
  • Interchangeable between systems or manufacturers
• Supports compliance and testing: This standard outlines mandatory testing such as:
  • Hydrostatic pressure tests
  • Non-destructive testing (e.g. X-ray, ultrasonic)
  • Fatigue or vibration tests

This ensures that each assembly can withstand operational stresses and support regulatory compliance.

• Improves reliability and lifecycle: Manufacturers follow this standard to produce assemblies with the following features:
  • Improved reliability under cyclic or dynamic loads
  • Longer service life reduces the need for frequent replacement or shutdown
  • Predictable performance to aid maintenance planning
• Facilitates international trade and collaboration: Having a recognized standard like PF.90088 enables companies from different countries or sectors to:
  • Collaborate more effectively
  • Sourcing parts globally with confidence
  • Reducing engineering estimates in procurement and integration
• Supports documentation and traceability: These and similar standards often require documentation for materials, manufacturing processes, and test results, ensuring:
  • Provides traceability
  • Helps with fault analysis
  • It is indispensable for certification and audits.

The test methods defined in this standard are:

• Functional tests:
  • Overpressure joint integrity testing
  • Leak control test
    • Leakage rate continuous compliance testing
  • Diameter expansion
  • Load test
    • Feature load testing
    • Joint integrity test
    • Virtual analysis of hoop stress under clamp load
    • Assembled pipe load/tensile test
  • Low temperature impact test
  • Tensile test
    • Subcomponent tensile test
    • Gear insert tensile test
    • Assembly or connected component testing
  • Fastener testing
    • Scrape test
    • Residual torque test
    • Gear insertion torque test
  • Pressure drop test
    • Prediction of pressure drop and flow behavior
    • Pressure drop bench test
  • Mold flow prediction
  • Structural noise, vibration and harshness testing
    • Panel inertance test (pressure difference causing change in volumetric flow rate of a fluid over time)
    • Bracket hardness
  • Airborne noise, vibration and harshness testing
    • Transmission loss test
  • Pressure cycle test
  • Thermal air/surge test
    • Engine program test
    • Body program test
  • Individual bracket durability analysis
  • Behavior against gritting
  • Push (ergonomics) test
• Security and regulatory testing
  • Homologation (approval)
• Reliability / durability tests
  • System and vehicle level testing
  • Design failure modes and effects analysis
  • Durability - Thermal protection (vehicle testing)
  • Durability (vehicle testing)
  • Corrosion (vehicle testing)
  • Power rating test (motor test)

Our organization, which has been supporting businesses across all sectors for years through a wide range of testing, measurement, analysis, and evaluation activities, has a strong team of employees who closely follow global developments in science and technology and are constantly improving themselves. In this context, we also provide testing services in accordance with the "Stellantis PF.90088 Performance Specification - Air Intake Systems - High-Pressure Pipe Assemblies" standard.