DARRINGTON GEAR OIL

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Case Study - before/after Gear Oil

ISO CODE ; 21/19/11

FILTRATION SAMPLING SITE VISIT REPORT EUROPEAN METAL RECYCLING A PLANT Your dedicated KLEENOIL Engineer contact details;

(was OUT OF RANGE)

GOOD–

SUMMARISED UPDATE

Jonathan Brough

TEL -07775 641250

• PARTICULATE:

NONE

john@kleenoil.co.uk

• CHEMISTRY:

STABLE

Matthew Johnson

• WEAR:

STABLE

TEL -07775 641247

• MOISTURE:

NOT REPORTABLE

matthew@kleenoil.co.uk

ADVISE – NONE

MACHINE DETAILS: GEAR BOX

What do your colour codes indicate?

GREEN is GOOD – ISO 19/16/15 or better

EXISTING FILTRATION Pressure filter s Air filtration By-pass filtration

AMBER is CAUTION - ISO 22/20/16 or worse

RED

is SERIOUS – ISO 24/23/18 or

1 X SDU9788KU85 HYDRAULIC

worse; ACTION NEEDED

This latest change was done ; CURRENT CHANGE (Qtr) We will contact site to arrange your NEXT CHANGE / SAMPLING DUE ; Around 30/10/25 (Qtr) - 30/07/25

If you need any assistance between quarterly visits, please do not hesitate to contact us on the above numbers

through our office – TEL; 01977 682810 ; sales@kleenoil.co.uk

Gearbox Oil Analysis –

Sample History

• Start Sample – 08.07.25 (Before Kleenoil) o Too dirty to carry out a particle count. ▪

Reason: Heavy contamination levels exceeded the calibration range of the particle counter, so no ISO code could be assigned. Oil also had a visible haze, indicating high solid & water contamination.

Key values: ▪

Viscosity: 115.1 cSt (in spec for gear oil grade) ▪ Water: 123 ppm (borderline high) ▪ PQ Index: 35 (high ferrous debris) ▪ Metals: Fe 59, Cu 60, Pb 38 — severe wear present ▪ Additives: Phos 237, Zn 29, Ca 46 (normal baseline)

• 2nd Sample – 15.07.25 (7 days after installation of Kleenoil) o Condition already improving: ▪ Viscosity: 117.7 (stable, no breakdown) ▪ Water: 71 ppm (↓ from 123 – filtration & settling already reducing moisture) ▪ PQ: 9 (↓ from 35 – less ferrous debris circulating) ▪ ISO: 24/22/15 (still dirty, but measurable – counts very high at >4 µm = 102,574/ml) ▪ Metals: Fe 20, Cu 22, Pb 27 — sharp reduction in wear metal levels within just 1 week ▪ Additives: trending slightly down as contaminated oil is diluted out, still functional • 3rd Sample – 21.07.25 (ongoing after 2 weeks with Kleenoil) o Marked improvement: ▪ Viscosity: 117.2 (stable) ▪ Water: 59 ppm (↓ further from 123 → 71 → 59 ppm – under control now) ▪ PQ: 3 (very low, ↓ from 35 start value – ferrous debris nearly eliminated) ▪ ISO: 21/19/11 ▪ 14 µm: 18/ml (↓ 92% from 227/ml) ▪ 6 µm: 2,684/ml (↓ 88% from 23,120/ml) ▪ 4 µm: 19,522/ml (↓ 81% from 102,574/ml) → Achieved a 3 - class improvement from 24/22/15 → 21/19/11 in just 2 weeks. ▪ Metals: Fe 8, Cu 5, Pb 21 — all trending down (wear generation slowing, old debris removed) ▪ Additives: P/Zn/Ca gradually falling as oil is cleaned — expected as contaminated fraction is removed.

Interpretation

1. Initial Condition:

o The gearbox oil was heavily contaminated with solids and water, causing “too dirty to count” status, high PQ, and significant wear metal presence. Oil had visible haze, confirming contamination. o Without intervention, this condition would have led to accelerated component wear, risk of gearbox failure, and shortened oil life. 2. After Kleenoil Install (1 week):

o Already a dramatic reduction in PQ (35 → 9), showing less ferrous debris.

o Water cut nearly in half (123 → 71 ppm).

o Wear metals also dropped significantly (Fe 59 → 20; Cu 60 → 22).

o Oil still dirty, but measurable ISO now possible.

3. After 2 weeks:

o ISO improved from 24/22/15 → 21/19/11 (equivalent to >80% particle reduction).

Water down to 59 ppm.

PQ nearly eliminated (35 → 3).

o Wear metals continue to fall (Fe 8, Cu 5, Pb 21).

o Viscosity and TAN remain stable — oil condition is healthy again.

Benefits Demonstrated

• Contamination control: From “too dirty to count” to world -class measurable cleanliness in 2 weeks. • Wear reduction: PQ and wear metals trending down confirms that abrasive debris has been removed, reducing further wear. • Water control: 123 → 59 ppm — moisture is being steadily removed, preventing corrosion and oil degradation. • Oil life extended: With TAN stable and contamination under control, the oil can remain in service much longer, avoiding costly full drain/replacement. • Component protection: Gearbox wear rate has slowed dramatically, protecting gears and bearings from further damage.

Conclusion

The gearbox has shown a dramatic turnaround in just 2 weeks with Kleenoil bypass filtration:

• From hazardous, dirty oil → to clean, dry, stable oil • PQ reduced by >90% • Water reduced by >50% • Wear metals cut by 60 – 90% • ISO improved by 3 classes

Moving forward: Routine sampling will ensure these improvements are sustained, while providing early warnings of any new issues (e.g. if wear metals trend back upward, or water spikes due to ingress).

This is clear proof of the value of permanent bypass filtration for extending gearbox and oil life, preventing failures, and saving costs.

Summary Report view

Client Name

A PLANT Gearbox

Machine Name

Site Name

Darrington

Report Date

Result

4 Micron 6 Micron 14 Micron Moisture (ppm) Client Button

21 July 2015 Pass 08 July 2025 Fail 15 July 2025 Fail

19522

2684

591

90000 60000 102574 23120

30000

1231

227

711

120000

100000

80000

4 Micron 6 Micron 14 Micron Moisture (ppm) Client Button

60000

40000

20000

Pass

Fail

21/07/2015

08/07/2025

15/07/2025

COMMENTS / SUGGESTIONS

LATEST REPORT ; Shows the three total particle counts that make up an ISO Code New oil - World Wide Fuel Charter Cleanliness Standard is ISO 18/16/13 (NAS7)

w 4 Micron - generally least damaging but potentially causes clogging and varnishing issues, especially on fine tolerances. 6 Micron - these act like sandpaper, causing scoring, pitting, and polishing wear on gears, pistons, and bearings. 14 Micro - At this size, particles are big enough to cut into metal surfaces with significant force during sliding or rolling contact. Moisture - BLUE - ppm - parts per million

RESULT - see notes

KLEENOIL UK LIMITED, FENTON LANE, LEEDS LS25 6EZ

01977 682810

sales@kleenoil.co.uk

Figure 1- THE PROGRESS OF CLEANSE

Figure 2 Gear oil before/after visual

Figure 3; the ferrous devbris is trapped onto the magnetic core

Figure 4; filter tops act as a patch test to see the level of debris prevented from re entering the system

Figure 5; a KLEENOIL MS2 with gear pump was used to achieve these results.

A X - Immediate Action C - Action B - Monitor A - No Action

A PLANT FINAL A PLANT FINAL

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

GEARBOX UNKNOWN FCC DARRINGTON

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

21/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Sample Details

Test Method

Units

Current Result

Previous #1

Previous #2

Lab No

- - - - - - - - -

552118142 21/07/2025

Sample Date

Meter Hrs Fluid Hrs Oil Added

0 0

0.00

Fluid Changed Filter Changed

No No

Lubricant Label No

Unknown

Physical Tests Viscosity at 40 C

ASTM D7279-14

cSt

117.2

Water

ASTM D6304 ASTM D6304

ppm

Water (% Wt)

% Wt.

0.0059

Particles

14µ 21µ 38µ

ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021

Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml

4 1

4µ 6µ

19522

2684

70µ

ISO Code PQ Index

Code

21/19/11

In-House

N/A

Oil Contaminants

Lithium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm

0 0 1 0

Potassium

Silicon Sodium

Water

In-House

Pos/Neg

Wear Metals Aluminium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm ppm ppm ppm

Chromium

0.2

Copper

5 8

Iron

Lead

Nickel

0.0

Tin

0 0

Vanadium Additives

Barium Boron

ASTM D5185-97 ASTM D5185-97

ppm ppm

0 1

Fluid and Condition Monitoring Services, Unit 3 Triangle Business Park, Oakwell Way, Birstall, Batley, West Yorkshire, WF17 9LU. Tel: 0113 201 2065 Email: Oillab@finning.co.uk. For more information, or to view your results online, please visit www.fluid-analysis.com This information is supplied for your benefit only and should not be relied on by any third party whatsoever.

Page 1 of 2

A X - Immediate Action C - Action B - Monitor A - No Action

A PLANT FINAL A PLANT FINAL

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

GEARBOX UNKNOWN FCC DARRINGTON

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

21/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Additives Calcium Magnesium Molybdenum Phosphorus

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm

3 0

205

Zinc

A - No Action A

Diagnosis: THE LEAD READING IS A LITTLE ELEVATED BUT OTHER WEAR READINGS GIVE US NO CAUSE FOR CONCERN. THE READINGS GENERALLY GIVE US NO IMMEDIATE CAUSE FOR CONCERN.

X - Immediate Action C - Action B - Monitor

Page 2 of 2

C X - Immediate Action C - Action B - Monitor A - No Action

A PLANT 2ND A PLANT 2ND

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

GEARBOX UNKNOWN FCC DARRINGTON

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

15/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Physical Tests

Sample Details

Test Method

Units

Current Result

Previous #1

Previous #2

Lab No

- - - - - - - - -

552118141 15/07/2025

120

Sample Date

100

Meter Hrs Fluid Hrs Oil Added

0 0

0.00

V40

Fluid Changed Filter Changed

No No

Lubricant Label No

Unknown

Current

Physical Tests Viscosity at 40 C

Particles

ASTM D7279-14

cSt

117.7

120K

Water

ASTM D6304 ASTM D6304

ppm

100K

Water (% Wt)

% Wt.

0.0071

Particles

80K

14 4 6 PQI

14µ 21µ 38µ

ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021

Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml

227

60K

40K

4µ 6µ

102574

20K

23120

Current

70µ

Oil Contaminants

ISO Code PQ Index

Code

24/22/15

In-House

N/A

Oil Contaminants

1.6

Lithium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm

0 0 2 1

Potassium

1.2

Na Si

Silicon Sodium

0.8

Water

In-House

Pos/Neg

0.4

Wear Metals Aluminium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm ppm ppm ppm

Current

Chromium

0.3

Copper

22 20 27

Iron

Lead

Nickel

0.2

Tin

1 0

Vanadium Additives

Barium Boron

ASTM D5185-97 ASTM D5185-97

ppm ppm

0 2

Page 1 of 2

C X - Immediate Action C - Action B - Monitor A - No Action

A PLANT 2ND A PLANT 2ND

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

GEARBOX UNKNOWN FCC DARRINGTON

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

15/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Wear Metals

Additives Calcium Magnesium Molybdenum Phosphorus

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm

3 0

216

Cr Cu Fe Ni Pb

Zinc

A - No Action C

Diagnosis: ACTION REQUIRED! THE LEAD READING IS A LITTLE ELEVATED BUT OTHER WEAR READINGS GIVE US NO CAUSE FOR CONCERN. THE PARTICLE COUNT IS RATHER HIGHER THAN TARGET (ISO 21/18/15). ASSUMING THIS IS A REPRESENTATIVE SAMPLE THEN STEPS MAY BE NEED TO BE TAKEN TO CLEAN UP THE OIL.

X - Immediate Action C - Action B - Monitor

Current

Page 2 of 2

C X - Immediate Action C - Action B - Monitor A - No Action

GEARBOX UNKNOWN FCC DARRINGTON A PLANT START A PLANT START

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

08/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Sample Details

Test Method

Units

Current Result

Previous #1

Previous #2

Lab No

- - - - - - - - -

552118140 08/07/2025

Sample Date

Meter Hrs Fluid Hrs Oil Added

0 0

0.00

Fluid Changed Filter Changed

No No

Lubricant Label No

Unknown

Physical Tests

Sample Observations

In-House

n/a cSt

Dirt Particles

Viscosity at 40 C

ASTM D7279-14

115.1

Water

ASTM D6304 ASTM D6304

ppm

123

Water (% Wt)

% Wt.

0.0123

Particles

14µ 21µ 38µ

ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021 ISO 4406:2021

Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml Counts/ml

- - - - - -

4µ 6µ

70µ

ISO Code PQ Index

Code

OUT OF RANGE

In-House

N/A

Oil Contaminants

Lithium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm

0 0 4 0

Potassium

Silicon Sodium

Water

In-House

Pos/Neg

Wear Metals Aluminium

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm ppm ppm ppm

Chromium

0.3

Copper

60 59 38

Iron

Lead

Nickel

0.1

Tin

1 0

Vanadium Additives

Barium

ASTM D5185-97

ppm

Page 1 of 2

C X - Immediate Action C - Action B - Monitor A - No Action

GEARBOX UNKNOWN FCC DARRINGTON A PLANT START A PLANT START

Unit Number Serial Number

KLEENOIL FILTRATION LTD

Customer Name

Make Model

Address

SHERBURN IN ELMET,WEST YORKSHIRE FENTON LANE,

Location

08/07/2025

Sample Date

Job No

GEAR OIL

Component Lubricant

Received Date

29/07/2025

Unknown unknown

Ian Burton

Interpreted By

Reported Date

04/08/2025

Additives

Boron

ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97 ASTM D5185-97

ppm ppm ppm ppm ppm ppm

Calcium

Magnesium Molybdenum Phosphorus

5 1

237

Zinc

A - No Action C

Diagnosis: ACTION REQUIRED! THE LEAD READING IS A LITTLE ELEVATED BUT OTHER WEAR READINGS GIVE US NO CAUSE FOR CONCERN. THE PARTICLE COUNT (ISO TARGET 21/18/15) CANNOT BE MEASURED DUE TO DEBRIS IN THE SAMPLE. ASSUMING THIS IS A REPRESENTATIVE SAMPLE THEN STEPS MAY BE NEED TO BE TAKEN TO REMOVE THIS DEBRIS AND CLEAN UP THE OIL.

X - Immediate Action C - Action B - Monitor

Page 2 of 2

Long-Term Benefits of Constantly Cleansed Gearbox Oil

1. Extended Component Life

• Reduced Wear: Clean oil dramatically lowers abrasive particle interaction between gears, bearings, and seals. • Lower PQ & Wear Metals: By keeping PQ and wear metals at negligible levels, surface fatigue, pitting, and scuffing are reduced, extending gearbox life expectancy.

2. Reduced Downtime & Failures

• Contaminated oil accelerates wear and raises the risk of sudden gearbox failure. • With ISO-clean oil, operators can expect fewer unplanned stoppages and lower repair/replacement costs.

3. Extended Oil Life & Reusability

• Stability: With contaminants, water, and metals removed, viscosity and TAN remain within specification for far longer. • Reusability: Gear oil can be safely used for multiple cycles rather than disposed, provided it is monitored (via regular sampling). This reduces waste oil disposal costs and supports sustainability goals. • Cost Efficiency: Instead of frequent oil changes, oil is maintained in service almost indefinitely, provided additives remain intact.

4. Improved Reliability of Additives

• Additive packages (anti-wear, anti-foam, rust inhibitors) degrade prematurely when contaminants accumulate. • Cleanse technology preserves additive integrity, ensuring the oil continues to perform as designed.

5. Energy Efficiency

• Clean oil reduces frictional losses and maintains film strength, improving energy transfer efficiency within the gearbox. • Less drag = less wasted power, cooler operating temperatures, and lower energy consumption.

6. Sustainability & ESG Gains

• Extending both oil and equipment life reduces waste oil generation, disposal needs, and new oil purchases. • Demonstrates proactive commitment to environmental performance.

Can the Oil Be Reused?

Yes. Once cleansed, gearbox oil can remain in service significantly longer than traditional change intervals — in some cases indefinitely.

• Condition Monitoring: Regular sampling should confirm viscosity, TAN, and additive levels remain in range. • Top-Up vs. Change: Instead of replacing the full volume, only minimal top-ups for losses are needed. • Best Practice: Continue Kleenoil filtration in a “kidney - loop” (offline constant clean) setup to keep the oil at target ISO and moisture levels. Summary: Running constantly cleansed gear oil ensures longer gearbox life, fewer failures, extended oil reusability, and measurable cost/environmental benefits.

Instead of “drain and replace,” the oil becomes a circulating asset, supporting both reliability and sustainability.

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