take control of repowering – be the one to choose what’s inside of your machine

© 2016 Sentient Science Corporation – Confidential & Proprietary

Take Control of RepoweringChoose What’s Inside Your Assets


Repowering? What’s Next?1. GEARBOX CONTROL 2. MANAGE TSA’S

3. MINIMIZE LOST PRODUCTION & MANAGE LIFE 4. LIFE EXTENSION – BEYOND PRO FORMA

Computationally test and understand the best GBX for each repowered asset. To protect yourself, obtain the Bill of Materials (BOM) and negotiate for serial defect protection.

Continue power production and minimize O&M costs during the 12-14 timeframe before change-over.

Know the right actions to take to make your newly repowered machine last beyond design life.

Take Control of Repowering - Choose What’s Inside Your Assets

REPOWEREDMACHINE

PRO FORMA& BEYOND


Repowering? What’s Next?1. GEARBOX CONTROL

Computationally test and understand the best GBX for each repowered asset.



MAKE

MODEL

RATING

COUNTRY OF ORIGIN

DESIGN STANDARDS

METROLOGICAL CHARACTERISTICS

LUBRICANTS

Gearbox Control1. Compare gearbox OEM offerings

2. Understand the impact different operating conditions will have on each turbine

3. Obtain the data to negotiate what gearbox is inside your machine



Case Study #1: DigitalClone® Live - Impact of Gearbox OEM Choice

GBX Supplier Differentiation and Selection→ Operators take actions to reduce O&M cost

increase by evaluating new gearbox and components life extension using DigitalClone before procurement

→ DigitalClone® prognostic modeling applied to the 1.5 MW gearboxes to identify the best supplier

→ DigitalClone® predicted Supplier 3 gearbox is the best due to relatively better bearings and gears design and manufacturing processes

Supplier 1Supplier 2Supplier 3Supplier 4

5 years 10 years 15 years 20 years

*Based on a 5 year history and 15 year forecast



2. MANAGE TSAs

Repowering? What’s Next?

To protect yourself, obtain the Bill of Materials (BOM) and negotiate for serial defect protection.



Managing Turbine Supply Agreements (TSA’s)Repowering gives the Operator insight for better negotiations

BOM Management: 1. Mandate as a condition of purchase the

BOM be provided at the subcomponent level for drivetrain components

2. We have tools to fill in the gaps for missing BOM components

3. If you want to have a BOM made for your particular wind farm, we can assist with non destructive investigation

Serial Defect T&C’s: 1. 20% defect rate should be maximum 2. Agree to a joint funded 3rd party RCA

investigator

OPC Tag List: 1. Transparency between OEM access and

owner access 2. Available API’s where OPC tags are protected

Design Conditions: 1. Environmental design conditions 2. Electrical and mechanical fatigue are direct

results, largely influenced by the operating conditions, which can be modeled

Additional Documentation: 1. Drawings of internal components 2. Full maintenance documentation



Case Study #2: Identifying Serial Defects with DigitalClone

Importance of Collecting and Tracking Bill of Material for Fleet Planning

Sentient Science can help operators with borescoping and communication with component suppliers to obtain correct bill of materials.


Supplier Rollers Cage

Supplier A =/= 14 Narrow

Supplier B 14

Supplier C =/= 14 Wide

Sentient Provides Best Practices to Identify Component Serial Number + Supplier with Borescoping Borescope

New Data from SupplierOriginal Data from Operator

Sentient Helps Obtain Accurate BOM Data

Sentient works with suppliers and borescope inspection found significant differences in the expected bill of material from the operator and the real bill of material in the turbines. The DigitalClone analysis led to hypothesis of failure for bull gears expected from poor material quality, higher stress from previous geometry, and material handing issues for this batch. Based on the updated bill of material data and high risk of failure in the batch, 2 additional turbines were updated to high risk of premature failure.


3. MINIMIZE LOST PRODUCTION & LIFE


Continue power production and minimize O&M costs during the 12-14 month timeframe before change-over.



Minimize Lost Production During Repower Change-over

1. 12-14 month timeframe between repower change-over

2. Manage asset life during construction period

3. Reduce O&M investments

4. Consider life extension options during time-gap: 1. Smart Derate2. Surface treatments 3. Fleet component Interchangeability

5. Use as “test bed”



Low Risk Opportunity to Pilot Potential Life Extension Innovations:



Case Study #3 – Using Physics Based DerateUsing System Models + Field Data from borescopes to manage gearing endurance limits specific to an asset


• Main shaft bearing clearance was assumed to be 2.5mm.

• Based on the full gearbox analysis, it is recommended to derate the turbine to 1.5MW to avoid Bull Gear teeth loss & surface damage.


Case Study #4: DigitalClone® Live – Action Lists for Life Extension

Uptower and Derate Actions

→ Sentient provided Watch List and Life Extension Action reports to customer during Dec. 2014

→ Long term and short term visibility to failure, uptower repair was made during scheduled maintenance activity, and zero unplanned downtime was incurred.

→ Traditional data analytics did not detect this failure

Butterfly Wings

Turbine ID DigitalClone Predicted MTOD

Damage Noticed Date

Action Taken for Life Extension

Life Extension, Months

A Sept, 2015 Oct, 2015 Uptower Replacement 33

B June, 2016 Aug, 2016 Derate 14




There are surface treatments, such as REWITEC®, that can be added to the gearbox while it’s in operation and have been shown to mitigate existing damage on components. This could be a more cost effective solution compared to replacing parts.

We’ve Created a Process for Customers to:

• Collect Borescope Reports from Damaged Turbines

• Classify the Damage Severity and Failure Mode of the Borescope Images, and Compare These to the “Before” Failure Mode and Severity in the Case Studies

• Make a Recommendation to our operators to consider surface treatments to “freeze” the damage of these components based on the case study

Case Study #5: Using Surface Treatments During Repowering Events

Evaluate Opportunities for Managing Component Damage


4. LIFE EXTENSION – BEYOND PRO FORMA


Understand the corrects actions to take to ensure your newly repowered machine last beyond design life.


REPOWEREDMACHINE

PRO FORMA& BEYOND



Operators and suppliers will know the earliest point in time when critical components will begin to fail and have options to extend life

Extending the Life for Newly Repowered Machines “Material Science Approach”


DigitalClone® Live – Site Analysis



Case Study #6: Life Extension Recommendations

List of Recommended Life Extension Actions and Option to Confirm

Acceptance


Financial Reporting to

Connect O&M Actions to

NPV/ROI of Decision Making


Case Study #6: Life Extension Recommendations

Track Life Extension

Actions Taken and Track

Overall ROI of Actions over

Time



Case Study #6: Financial InputsFinancial Data Provided to Connect O&M to ROI Decisions

Financial Inputs of Site Included

in Software



Repowering? What’s Next?1. GEARBOX CONTROL 2. MANAGE TSA’S

3. MINIMIZE LOST PRODUCTION & MANAGE LIFE 4. LIFE EXTENSION – BEYOND PRO FORMA

Computationally test and understand the best GBX for each repowered asset. To protect yourself, obtain the Bill of Materials (BOM) and negotiate for serial defect protection.

Continue power production and minimize O&M costs during the 12-14 timeframe before change-over.

Know the right actions to take to make your newly repowered machine last beyond design life.


REPOWEREDMACHINE

PRO FORMA& BEYOND

take control of repowering – be the one to choose what’s inside of your machine

Engineering