Experiencing Unplanned Downtime? Use Vartech
Plant managers have a lot of challenges to overcome daily.
However, nothing is more dreaded than the sudden shutdown of a production unit or line because of equipment failure. According to recent studies and research, almost 82% of companies have experienced unscheduled shutdowns in the past three years, costing the industrial plant up to $260,000 an hour, cessation of delivery services to customers, and overall loss of customer trust and future sales.
These disastrous consequences mean that plant managers need to be watchful about averting unexpected outages. But, reality and research prove otherwise. Research survey reveals that most plant managers do not know when their vital production equipment is due for maintenance, upgrade, or replacement. According to the International Society of Automation, industrial facilities lose nearly $650 billion per year to unplanned equipment outages and missed production.
These alarming figures and statistics reveal that unplanned downtime is more than just a headache, one that most plant managers struggle with.
What causes these unplanned downtimes?
The big question that remains is the reason behind these unplanned downtimes. Three common causes of unplanned outages and shutdowns have been highlighted that need urgent attention in order to prevent financial losses.
Reactive maintenance processes, where maintenance teams wait until there is an observed issue with equipment have been mentioned as a common reason. The problem with this process is it relies on a technician to find and identify a problem, such as a leaking pipe or damaged part before action is taken. The drawback of this process is that a problem could go unnoticed for some time if it’s not obvious and could become urgent by the time someone finds it. This often results in maintenance managers quickly re-prioritizing and communicating with their staff to fix the issue. Lack of spare parts could lead to delays of several days to order and get an additional part. Meanwhile, operations could be hindered or even shut down if the issue is serious.
A lack of clarity into maintenance work processes is another critical issue leading to unexpected downtime. Mainly because, managers issue work orders to field technicians in paper dossiers leaving them uninformed on a daily basis of what’s happening in their plant.
Poor communication between supervisors and field techs, precipitated by paper-based work order management processes, could also cause a mix-up.
Solution to the big question: Vartech
Caltex lubrication experts have created select GST ® Advantage turbine oils with VARTECH™ Technology. Using proprietary triple-action technology, Vartech ISC, in one sweeping move, can indirectly do away with unplanned downtimes.
How?
Even the smallest amount of varnish can lead to poor system performance and equipment failures. Valves stick, bearings overheat, components wear out, oil inlets and filters clog, and the internal mechanics of your turbine can malfunction. These issues worsen over time as more varnish builds up, resulting in reduced oil life, poor equipment performance, and untimely stoppages.
Vartech’s two-step, clean-and-control solution can help you protect equipment from varnish and ensure peak productivity in your operation. The advanced lubrication chemistry used in VARTECH™ Technology prevents the formation of varnish precursors, products of oil degradation that can deposit on internal surfaces and build up over time. Additionally, after the existing varnish has been scrubbed from your gas turbines, Vartech’s advanced lubrication chemistry prevents the precursors that can form in your oil stream, deposit on internal surfaces and eventually become varnish. Moreover, Vartech ISC is also compatible with the in-service oil for optimum operational flexibility while maintaining performance during the cleaning cycle that prepares the system for change out to fresh oil.
Learn more about how Vartech can beat varnish and prevent unplanned shutdowns.
