Assessing the Impact of Surface Treatment Solutions to Extend Asset Life

© 2016 Sentient Science Corporation – Confidential & Proprietary


Assessing the Impact of Lubrication Solutions to Extend Asset Life

EnergyWind Energy (17,000 assets under contract) and O&G

Who is Sentient Science?A Trusted Third Party to Enable Life Extension of Rotating Equipment

Extend the Remaining Useful Life (RUL) through Prognostics

Industrial Equipment – Mining, Construction and Forestry, Agriculture, Trucking

Aerospace – Rotorcraft, Fixed Wing, and Defense (15 years)

Key Verticals Served

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Three Life Extension Services 1. DigitalClone®

o Materials-Based Computational Testing (SaaS)

2. DigitalClone® Live for Operatorso For Life Extension of Gearboxes, Main

bearings, Pitch Bearings

3. DigitalClone® Live for Supplierso Interface Suppliers with Operators

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DigitalClone® Live for Operators• Sentient Science is deploying DigitalClone® Live for Operators globally and

has 18,000 wind turbines under contract.

• The prognostic models use tribology, material microstructure, and multi-physics to simulate and know the earliest point in time when critical components in their wind turbine gearbox will begin to fail.

• This data allows asset, operations and risk managers to simulate and plan life extension activities such as uptower component replacement, physics-based de-rating, changes in lubrication and generate 18 month rolling O&M spending plans.

• DigitalClone® Live allows purchasing managers, for the first time, to buy replacement components based on multi-year forecasts knowing the calculated lifing projections of one supplier over another on gearbox life.

• We call this Buy on Life™ not just price, and it is changing the way operators are looking at extending the life of their assets.

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DigitalClone® How to Extend Life of Assets

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Introducing DigitalClone® Live for SuppliersWith operator approval, DigitalClone® Live for Suppliers will automatically provide sales leads to your organization through a web portal, defining the specific asset location and configuration to be serviced, component or service needed to extend gearbox life, outcomes and buyer contacts.Sentient is developing this new service to help better match supply and demand, to improve efficiencies, reduce the costs for extending gearbox life, and to make more money for operators and suppliers.

Sentient has the following Supplier programs for lubricant providers:

1.Access to the Sentient DigitalClone® Live Operators Network to find leads and pipeline for your company

2.Marketing programs to expose your brand in the Sentient network

3.Field Trial and DigitalClone® simulation programs to build data showing the performance of your products within the operators DigitalClone® gearbox models

4.Transaction agreements with Sentient paid only from new revenue

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REWITEC® Engagement SummaryBusiness Challenge to Solve:• Operators are looking to extend the life of GE 1.5MW Winergy 4410.2 GBXs that are slightly damaged

Project Objective • Develop DigitalClone prognostic model to quantify the effect of REWITEC DuraGear W100 treatment of

GE 1.5 SLE Winergy 4410.2 gearbox• Predict and compare the fatigue performance of “As Is” components with “To Be” components with

surface roughness inputs from REWITEC

Project Timeline:

Step 6:Final Report &

Recommendation

Step 5:GBX Life Extension for Winergy 4410.2

with DuraGear W100 Treatment

Step 4:DigitalClone

Simulation for Bearings & Gears

Step 3:Bearing and Gear Material Model Development

Step 2:Load Analysis for Winergy 4410.2

GBX

Step 1:Transfer of Data and Materials

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Assessing the Impact of Lubrication Solutions to Extend Asset Life 8

Sentient Science History

2001-2016$25M in R&D Funding

From the world’s largest operator of heavy equipment

2010NASA Validation

Of game changing technology,

DigitalClone®

2014Tibbett’s Award

White House honors DigitalClone® technology-

“decoding the Material Genome”

April 2016New Energy Pioneer Award

Michael Bloomberg honors commercial

impact of DigitalClone® technology in Sentient’s 1st Clean Energy market



Load Case Weibull, Life/Eta

Weibull, Slope

300 HP Run-out Run-out1021 HP 5.14E+07 1.721379 HP 1.26E+07 3.322042 HP 7.49E+06 3.841731 HP 2.97E+06 4.28

Surface stress = -1200 MPa

Surface stress = -1000 MPa

1E+6 4E+6

• Sentient results matched the Boeing rotorcraft gear design life under loading conditions equivalent to those experienced during the qualification testing

• DigitalClone® assists in increasing the gearbox ratings

Apache Spiral Bevel Gear ValidationExample of Sentient Science’s Previous Surface Work

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Technical Step #1: Transfer of Data and MaterialREWITEC® Field Trails & Available Data

• REWITEC® had extensive testing and field trials and approval by GE to be used in after warranty turbines

• REWITEC® had the correct inputs measured during the field trials that are inputs into the DigitalClone® modeling process

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• FE-8 Test at University Mannheim• Roughness Analyses by NanoFocus AG• Test run at load of 80 kN for 80 Hrs.• Surface roughness and weight loss was analyzed after 80 Hrs.

Technical Step #1: Transfer of Data & MaterialREWITEC® Test Details for Bearings Roughness Input to DigitalClone® Simulation

FE-8 Test – Gear Oil

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Technical Step #2: Gearbox Load Analysis

Wind Turbine Operational Data

BOM

Oil Properties

Geometry & Configuration

GBX Prognostic Model

• Multi-body Dynamics system model was created in Modelica that translates forces from the hub to the individual components.

• Wind loads are being applied on DigitalClone MBD system model to calculate global forces and moments on individual components.

Multi-body Dynamics (MBD) GBX Loads and Life

Forces and Moments

DigitalClone® System & Component Models

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Technical Step #3: Material Model Development

To obtain the following technical details from gears and bearing segments as inputs for DigitalClone® Model• Grain size and morphology• Case microstructure, core microstructure,

case-core transition region microstructure • Defects, non-metallic inclusions size

distribution, if any• Material imperfections, retained austenite,

grind burn etc.• Residual stress analysis• Surface roughness analysis

Based on Winergy 4410.2 Material Analysis

EDM Sectioned Bearing Segment

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Technical Step #4: Mixed EHL Model


Lubrication Testing & Surface Treatment

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Technical Step #5: DigitalClone® Life SimulationIntermediate Pinion Gear – at 1.5MW rated Power

High Speed IMS Bearing DW– Inner Race at 1.5MW rated Power

Contact Stress 1.7 GPa

L10 Life Operational Hrs.



“As Is” 4,239.70 5.58E+05 1.66E+07REWITEC®

“To Be” 54,871.61 8.89E+07 1.06E+10

Life Improvement 12.9 159.3 633.8

“To Be”“As Is”

“To Be”“As Is”

Ge 1.5 SLE Winergy 4410.2 HSIS DW bearing life (L10) improved by a factor of 12.9 with REWITEC® treatment (“To Be”)

Contact Stress L10 Life Operational Hrs.



“As Is” 787.7 2,678.1 27,443.9REWITEC®

“To Be” 1,405.0 9,928.8 66,809.7

Life Improvement 1.8 3.7 2.4

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Technical Step #6: Life ResultsWinergy 4410.2 GBX Life Extension using DuraGear® W100

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Executive SummarySentient Science has a long history of life extension modeling within aerospace and wind turbine industries for owner-operators

We have helped our wind turbine owner-operator customers identify critical drivers of gearbox failures, and they have mandated us to deliver how many will fail, what should they replace it with, and put them in touch with new life extension solutions

REWITEC® reached Sentient Science to evaluate how to enter the U.S. wind market after much field trial and testing in EU and China. Sentient Science life extension study showed 2x-3.3x improvement.

Opportunities for operators to evaluate ROI on their assets:o Apply on GE 1.5MW Fleeto Apply on Vestas, Siemens, Acciona, Gamesa Turbineso Main Bearing Life Extensiono OEMS and ISPSo Insurance Companies

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Engineering

Assessing the Impact of Surface Treatment Solutions to Extend Asset Life