Reducing Costs with Digitalization

© 2016 Sentient Science Corporation – Confidential & Proprietary

Title: Presenter:


Sentient Science Materials Science Differentiation1. Asset Management for Operators 2. Computational Testing & Reconfiguration for Suppliers

☑ Life Extension☑ Root Causes☑ Predict Earlier

Key Industries Served

WIND ENERGY • 22,000 assets under contract globally

AEROSPACE• Rotorcraft, Fixed Wing, & Defense• (15 Years of R&D)

RAIL• Wheel Rail Interface• New Market for Sentient

Sentient Science is a trusted third party enabling life extension of rotating equipment through a digital platform, connecting operators and suppliers through asset actions that lowers the cost of energy.WindEurope 2017 - Give me the BOM


What's New at Sentient Science?

1. New Product: DigitalClone Bearing available beginning of 2018 as part of our strategy to enable suppliers to create their own DigitalClone life models

2. We have Business Value Assessments (BVA) to share on how operators are reducing costs with DigitalClone Live

3. We have 2 digitalization panel sessions at the booth1. Tuesday & Wednesday at 13:00

4. We have a jazz band and party Tuesday night starting at 16:00

5. Do you like scotch? Drop your card to win €400 bottle of scotch


Small Data (10 Yrs R&D) No Physical Test needed

Material science-based approach to predict life & Life Extension through asset actions

FEA (20 Yrs)+Physical TestStatistics-based computational method to

predict how a product reacts to real world forces

Big Data (30 Yrs)+Physical TestComputational analysis of large data sets that

reveal patterns & trends to predict behavior

•Prognostics

• Insight into performance

• Sensor & Condition Based Monitoring

•Predictive Health Maintenance

•Assumption-based decision assistance

• Insight into asset performance

• Sensor & Condition Based Monitoring

•Corrective Maintenance

•Material Science

•No Sensors

• SCADA monitoring

• Life Extension Solutions

•Planned Predictive Maintenance

•Visibility Today Through 30 Years

II Annual International Conference on Life Extension of Wind Farms

“From Big Data to Small Data”

Sen

tien

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orp

. -

Pro

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etar

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Pri

vate

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New

Development

• Win new deals

• Competitive PPA biding

• Buy on Life & Price

• Optimize suppler choices

Business

Strategy

• Optimal Governance by digitizing wind fleets

• Integration with existing MAXIMO and other IT systems

• Optimize Key Performance Indicators to lower Cost of Energy

• Benchmark performance against industry competitors

Operations

Management• Lower the cost of asset operations

• Reduce technical visits due to bundling & false alarms

• Reduce costs from scheduling technician time and

equipment

Asset

Management

• 18 month rolling budgets and forecasts

• Avoid down-tower rebuilds with increased up-tower

replacements

• Reduce mobilization cost by bundling crane visits

• Avoid downtime with inventory available

Risk

Management• Reduce insurance and extended warranty

costs

• Reduce annual gearbox replacements with

preventative O&M recommendations

• Reduce long-term gearbox O&M cost with

“right first time” procurement

• Reduce insurance premium from risk

management

Supply

Chain• Improve terms and costs with key suppliers

• Reduce risk of exceeding O&M budgeting

• Reduce inventory storage required to mitigate failure risk

• Reduce unit cost of gearbox purchases with long-term

agreements

DigitalClon

e Lifing

Model

Reducing Costs with Digitalization


“As Is”

DigitalClone® provides the Return on Investment (ROI) and quantifies the life extension achieved for aftermarket replacements

DigitalClone® to quantify “what-if” scenarios to extend Remaining Useful Life (RUL)

“To Be”Years Until Gearbox FailureYears Until Gearbox Failure

Forward Visibility to Compare Supplier PerformanceCase Study #1


DigitalClone® predicts bearing life based on material microstructure, surface finish, and

material quality at the specific location and stresses experienced, e.g.: GE 1.5 SLE Gearbox

Forward Visibility to Predict Gearbox LifeCase Study #2

Bearing

Supplier

Hardness (Ra)

Range 0 to

4500 um

depth

Microstructure

Inclusions

Microstructure

Quality

A 60–58 HRC

B

60-53 HRC (Design

requirement >58

HRC)

Dig

ita

lClo

ne

®S

imu

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HSS Bearing DigitalClone Comparison

BEST BEST BEST

Stress / Life Curve

Cycles to Damage (L66)

Ma

x C

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Pre

ss

ure

(M

Pa

)

Stress – Life Curve

A

B

Better Life

Bett

er

Str

ess P

erf

orm

an

ce BEST


• Fleeet-wide assessment on GE 1.5MW gearboxes

• DigitalClone® predicts O&M cost increase over the next 6 years

• DigitalClone® provides operators actions to reduce O&M costs & enabling

turbine life extension by …

1. Optimizing Uptower component replacements

2. Gearbox upgrades & operational changes (Lubricants, Derate/Uprate)

3. Major component long lead time planning

4. Scheduled versus unscheduled maintenance

5. Evaluate new gearbox & components life extension before procurement

Forward Visibility to Predict Failure Rates

Supplier 1Supplier 2Supplier 3Supplier 4

5 years 10 years 15 years 20 years

Case Study #3

GE 1.5 MW Fleet Failure-Rate Predictions Gearbox Supplier Differentiation through DigitalClone®


DigitalClone® Provides Operators with Forecasts for Component Replacement over 4 years to Extend Life

Forward Visibility to Increase Uptower vs. Gearbox Replacement

Case Study #4

YearGBX

Replaced% GBX

FailuresCost$M Year

IM/HS Replaced

Planet Replaced

% Replaced

Cost$M

2016 100 3.6% 30.0 2016 60 24 3.1% 4.3

2017 110 4.0% 33.0 2017 75 30 3.8% 5.2

2018 115 4.2% 34.5 2018 85 34 4.3% 5.9

2019 121 4.4% 36.3 2019 98 39 5.0% 6.9

Total 446 16.2% $ 133.8 Total 318 127 16.2% $ 22.3

Option 1 · Gearbox Replacement Option 2 · Uptower Component Replacement

Customer XWTG Model GE 1.5 Total Units 2,748


Materials Science. Digitalization. Life Extension.

• Prognostics have evolved to contribute to lower the COEo Big Data

• Computational analysis of large data sets

• Reveals patterns & trends to predict behavior

o FEA• Statistics-based computational method

• Predicts how products react to real world forces

o Small Data• Uses a material science-based approach

• Predicts life & Life Extension through asset actions

• DigitalClone® combines material science with data science• Simulates how components interact under actual operating conditions

• Predicts when cracks initiate in the microstructure prior to failure

Materials Science Prognostic Models to Reduce Risk = CostA Digital Platform Connecting Operators and Suppliers


Learn More and Meet the Team!

Sentient Presentation Schedule WindEurope 2017

1. Introducing DigitalClone Live

2. Duke Energy Case Study

3. Main Bearing RCA

4. How to Value Digitalization

5. DigitalClone Live Product Update

6. Why Data Science Alone Wont Lower the Cost of Energy

7. Moventas XL Life Extension Program

9. Rewitec Additives to Extend Gearbox Life

10. DigitalClone Bearing Product Release

11. Wind Loads Modeling

12. Data Fusion: Material Science & Data Science

13. Drivetrain Modeling

14. Reducing Costs with Digitalization

WindEurope 2017 - Give me the BOM

Reducing Costs with Digitalization

Engineering

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