DARRINGTON GEAR OIL

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.

o

PQ nearly eliminated (35 → 3).

o

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.