ASTM D7874-13
(Guide)Standard Guide for Applying Failure Mode and Effect Analysis (FMEA) to In-Service Lubricant Testing
Standard Guide for Applying Failure Mode and Effect Analysis (FMEA) to In-Service Lubricant Testing
SIGNIFICANCE AND USE
5.1 This guide is intended as a guideline for fluid analysis programs and serves as an initial justification for selecting fluid tests and sampling frequencies. Plant operating experience along with the review and benchmarking of similar applications is required to ensure that lessons learned are implemented.
5.2 Selection of proper fluid tests for assessing in-service component condition may have both safety and economic implications. Some failure modes may cause component disintegration, increasing the safety hazard. Thus, any fluid test that can predict such conditions should be included in the condition-monitoring program. Conversely, to maintain a sustainable and successful fluid-monitoring program, the scope of the fluid tests and their frequency should be carefully balanced between the associated risks versus expected program cost savings and benefits.
5.3 The failure modes monitored may be similar from one application to the next, but the risk and consequences of failure may differ.
5.4 This analysis can be used to determine which in-service lubricant analysis tests would be of highest value and which would be ineffective for the failure modes of interest. This information can also be used to determine the best monitoring strategy for a suite of failure modes and how often assessment is needed to manage the risk of failure.
SCOPE
1.1 This guide describes a methodology to select tests to be used for in-service lubricant analysis. The selection of fluid tests for monitoring failure mode progression in industrial applications applies the principles of failure mode and effect analysis (FMEA).
1.2 Although typical FMEA addresses all possible product failure modes, the focus of this guide is not intended to address failures that have a very high probability of unsafe operation as these should immediately be addressed by other means.
1.3 This guide is limited to components selected for condition-monitoring programs by providing a methodology to choose fluid tests associated with specific failure modes for the purpose of identifying their earliest developing stage and monitoring fault progression. The scope of this guide is also focused on those failure modes and their consequences that can effectively be detected and monitored by fluid analysis techniques.
1.4 This guide pertains to a process to be used to ensure an appropriate amount of condition monitoring is performed with the objective of improving equipment reliability, reducing maintenance costs, and enhancing fluid analysis monitoring of industrial machinery. This guide can also be used to select the monitoring frequencies needed to make the failure determinations and provide an assessment of the strengths and weaknesses of a current condition-monitoring program.
1.5 This guide does not eliminate the programmatic requirements for appropriate assembly, operational, and maintenance practices.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
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Designation: D7874 − 13
Standard Guide for
Applying Failure Mode and Effect Analysis (FMEA) to In-
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Service Lubricant Testing
This standard is issued under the fixed designation D7874; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 2. Referenced Documents
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2.1 ASTM Standards:
1.1 This guide describes a methodology to select tests to be
D7684 Guide for Microscopic Characterization of Particles
used for in-service lubricant analysis. The selection of fluid
from In-Service Lubricants
tests for monitoring failure mode progression in industrial
D7720 Guide for Statistically Evaluating Measurand Alarm
applications applies the principles of failure mode and effect
Limits when Using Oil Analysis to Monitor Equipment
analysis (FMEA).
and Oil for Fitness and Contamination
1.2 Although typical FMEA addresses all possible product
2.2 IEC Standard:
failure modes, the focus of this guide is not intended to address
IEC 60812 Analysis Techniques for System Reliability—
failures that have a very high probability of unsafe operation as
ProcedureforFailureModeandEffectsAnalysis(FMEA),
these should immediately be addressed by other means.
2006
1.3 This guide is limited to components selected for
condition-monitoring programs by providing a methodology to
3. Terminology
choose fluid tests associated with specific failure modes for the
3.1 Definitions:
purpose of identifying their earliest developing stage and
3.1.1 cause(s) of failure, n—underlying source(s) for each
monitoring fault progression. The scope of this guide is also
potential failure mode that can be identified and described by
focusedonthosefailuremodesandtheirconsequencesthatcan
analytical testing.
effectively be detected and monitored by fluid analysis tech-
niques.
3.1.2 component incipient failure, n—moment a component
begins to deteriorate or undergo changes that will eventually
1.4 This guide pertains to a process to be used to ensure an
lead to the loss of its design function.
appropriate amount of condition monitoring is performed with
3.1.2.1 Discussion—This moment may not be easily detect-
the objective of improving equipment reliability, reducing
ablebecauseofsensitivitylimitationsofmonitoringinstrumen-
maintenance costs, and enhancing fluid analysis monitoring of
tation or a lack of measurable change in performance charac-
industrial machinery. This guide can also be used to select the
teristics or both.
monitoring frequencies needed to make the failure determina-
3.1.3 criticality number, C, n—product of the severity (S)
tions and provide an assessment of the strengths and weak-
and occurrence (O) numbers for a given failure mode’s causes
nesses of a current condition-monitoring program.
and effects.
1.5 This guide does not eliminate the programmatic require-
3.1.4 design function, n—function or task that the system or
ments for appropriate assembly, operational, and maintenance
component should perform.
practices.
3.1.5 detection ability number, D, n—ranking number that
1.6 This standard does not purport to address all of the
describes the ability of a specific fluid test to successfully
safety concerns, if any, associated with its use. It is the
detect a failure mode’s causes or effects. A scale is used to
responsibility of the user of this standard to establish appro-
grade detection ability numbers; see an example in 6.4.7.
priate safety and health practices and determine the applica-
3.1.6 effect(s) of failure, n—potential outcome(s) of each
bility of regulatory limitations prior to use.
failure mode on the system or component.
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This guide is under the jurisdiction of ASTM Committee D02 on Petroleum
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Products, Liquid Fuels, and Lubricants and is the direct responsibility of Subcom- For referenced ASTM standards, visit the ASTM website, www.astm.org, or
mittee D02.96.04 on Guidelines for In-Services Lubricants Analysis. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Current edition approved Oct. 1, 2013. Published October 2013. DOI: 10.1520/ Standards volume information, refer to the standard’s Document Summary page on
D7874-13. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
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D7874 − 13
3.1.7 failure-developing period, FDP, n—period from com- 4. Summary of Guide
ponent’s incipient failure to functional failure.
4.1 This guide is designed to aid the user to optimize their
3.1.8 failure mode, n—physical description of the manner in
condition-monitoring program.
whic
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