The Problem

Varnish formation in turbine and hydraulic oils leads to sticky servo valves, bearing distress, reduced heat transfer, and forced outages. High operating temperatures and oxidation accelerate the issue — particularly in gas and steam turbines.

The Solution

• Sub-micron filtration

• Insoluble and soluble varnish removal

• Oxidation-resistant lubricants

• Continuous oil condition monitoring

• Proactive contamination control

How Exterra Helps

We assess varnish risk using oil analysis and system reviews, then implement targeted removal technologies and preventative strategies. The result: stabilised control systems, longer oil life, and reduced risk of unplanned shutdowns.

The Problem

Undetected steam, gas, or compressed air leaks increase energy consumption, reduce efficiency, and create safety and compliance risks.

The Solution

• Ultrasound-based leak detection

• Steam trap inspection programs

• Compressed air system audits

• Routine monitoring and reporting

How Exterra Helps

Using advanced ultrasound technologies, we help you identify energy losses that are invisible to the eye. This reduces wasted energy, improves plant efficiency, and supports emissions reduction goals.

The Problem

Oil analysis data is often underutilised or misinterpreted, leading to missed early warnings or unnecessary oil changes.

The Solution

• Structured oil sampling programs

• Expert data interpretation

• Trend analysis and failure mode identification

• Actionable maintenance recommendations

How Exterra Helps

We don’t just provide test results — we provide insight. Our team helps you interpret data in context, identify root causes, and implement corrective actions that extend component life and reduce downtime.

The Problem

Electric motor failures are frequently caused by bearing wear, contamination, and incorrect lubrication practices — not electrical faults.

The Solution

• Ultrasound-assisted lubrication

• Grease selection optimisation

• Contamination control upgrades

• Grease analysis programs

How Exterra Helps

We transition your lubrication practices from time-based to condition-based. By improving grease application and contamination control, we help extend bearing life and reduce unexpected motor failures.

The Problem

Fuel contamination — water, particulates, and microbial growth — reduces combustion efficiency, damages injectors, and threatens standby reliability.

The Solution

• High-efficiency fuel filtration

• Water separation technologies

• Fuel polishing systems

• Additives to improve lubricity and cleanliness

How Exterra Helps

We assess fuel quality risks and implement filtration and treatment solutions that protect engines, stabilise fuel systems, and ensure dependable start-up performance.

The Problem

Most lubrication failures originate from contaminants entering the system — dirt, moisture, and airborne particles.

The Solution

• Desiccant breathers

• Sealed transfer systems

• Clean storage and handling practices

• Contamination control audits

How Exterra Helps

We design site-wide contamination control strategies that reduce wear rates dramatically. Prevention is always more cost-effective than removal.

The Problem

Once contaminants are inside the system, they accelerate wear, trigger varnish formation, and reduce component life.

The Solution

• High-efficiency oil filtration

• Water removal systems

• Varnish mitigation technologies

• Offline kidney-loop filtration

How Exterra Helps

We deploy filtration solutions matched to your system’s operating conditions, restoring oil cleanliness and protecting high-value assets.

The Problem

Poor sampling practices lead to unreliable data and incorrect maintenance decisions.

The Solution

• Engineered sampling points

• Vacuum and live-zone sampling methods

• Standardised procedures

• Training for technicians

How Exterra Helps

We design and implement best-practice sampling programs that ensure repeatable, reliable data — enabling confident maintenance decisions.

The Problem

Electrostatic discharge within oil systems can damage bearings, accelerate oil degradation, and create hidden reliability risks — particularly in high-flow, low-conductivity systems.

The Solution

• Electrostatic discharge filtration media

• Conductivity optimisation

• Flow management strategies

• System design review

How Exterra Helps

We assess your risk of static discharge and implement mitigation strategies that protect both oil and hardware from premature degradation.