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Duke Energy - Case Study

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Sentient Science WindEurope 2017 Booth Presentations

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Duke Energy - Case Study

  1. 1. Duke Energy – Case Study Wesley Thomas Vice President, Major Accounts
  2. 2. 2 Why Act – Duke Example Business Problems to Solve 250MW GE 1.5MW Midlife Crisis • Increasing Failure Rate at 5+ Year • Reduce Requirement for Multiple Technician Visits, and Life Extension 201MW MIT 2.4MW Supply Chain • Oldest assets, known gearbox failure • Gearbox 2-3x cost of replacement due to supply chain limitations 669MW Siemens 2.3MW EOW • Gearbox and main bearing failures • Require end-of-warranty and life extension support to increase claims Duke Energy – Case Study – WindEurope 2017 $
  3. 3. Duke Introduced to DigitalClone® Live Software for Operators Series of Projects in Different Functional Areas Duke Energy – Case Study – WindEurope 2017 Functionality Deliverable Benefit EDPR Action Value DigitalClone Live Watch List (0-12 Months) List of Assets with <12 Months MTOD O&M Scheduling and Bundling Inspect Watch List Assets To be defined in BVA DigitalClone Live Life Extension Recommendations Recommend Best Life Extension Action Prevent and Delay Expensive Failures Execute Life Ex. Action To be defined in BVA DigitalClone Live Watch List (18-60 Months) List of Assets with 12-60 Months MTOD Asset Man. Budgeting, Supply, Services Strategies Negotiate Services and Supply Agreement To be defined in BVA DigitalClone Live Supplier Comparison Comparison of Bearing Vendors for Uptower Replacement Reduce Long-Term Failure Rates Select Vendor based on Return on Investment To be defined in BVA Digitalization and Data Management Integrate DigitalClone Live in RMS Optimize Reporting and Input Plan to Integrate IT and Reports To be defined in BVA
  4. 4. © 2016 Sentient Science Corporation – Confidential & Proprietary Duke Energy O&M Coverage – Where DigitalClone Live Fits Duke Energy – Case Study – WindEurope 2017 Condition Monitoring System & DCL Watch List Borescope Replace/Repair Buy New Part Internet of Things DigitalClone Watch List (0-12 Months) Vibration Sensors Oil Analysis Work Orders Images Reporting Tracking New Asset Health Vendor Comparison Future Financial Risk Investment Plans Current Asset Health Replace Gearbox Replace Subcomponent In-Situ Action – Physics- Based Derate
  5. 5. Duke Energy Phase I Results for DigitalClone Live Duke Energy Invests in Digitalization to Reduce Costs & Minimize Impact of Fleet Failure Rate Using DigitalClone® Live Duke Energy – Case Study – WindEurope 2017 • Corporate goal of 35% cost reduction due to self-operation even as fleet ages • Already used condition monitoring tools to analyze vibration data for diagnostic fleet maintenance • Tested DigitalClone Live Watch List (0-12 Months) to help evaluate business case • GE 1.5MW highest priority
  6. 6. Duke Energy Phase I Results for DigitalClone Live Duke Energy Invests in Digitalization to Reduce Costs & Minimize Impact of Fleet Failure Rate Using DigitalClone® Live Duke Energy – Case Study – WindEurope 2017 • 11 of 109 GBXs predicted damage within 12 mo. • 7 turbines were inspected • 100% detection of damage to the gearboxes on the Watch List • 70% detection of damage to the top two critical subcomponents within the gearbox system • 0% were on CMS Watch List
  7. 7. © 2016 Sentient Science Corporation – Confidential & Proprietary Duke Energy Asset Management Coverage – Where DigitalClone Live Fits Duke Energy – Case Study – WindEurope 2017 Watch List and Risk Ranking Intervention Strategies Investment Plan (Budgets) Inventory Strategic Suppliers Risk Management Current Asset Health What has occurred? What will occur? Timing and Priorities Recommendations Repair/Replace Scenario Planning Optimize ROI Procurement How Much to Buy? Who to Buy From? Contract T&CS Financial Analysis O&M Costs of Actions Preventative Actions Budget Justification
  8. 8. © 2016 Sentient Science Corporation – Confidential & Proprietary Duke Success Criteria #1 Expectations to find new damage and find damage early Does not replace existing CBM Duke Energy – Case Study – WindEurope 2017
  9. 9. © 2016 Sentient Science Corporation – Confidential & Proprietary Duke Success Criteria #2 Duke Energy was the first owner- operator to obtain bill of material from OEM Duke owns the BOM, the OEM should provide the data Control of Your BOM is CriticalDuke Energy – Case Study – WindEurope 2017
  10. 10. Duke Energy – Case Study – WindEurope 2017 Duke Success #3 – Clear Alignment with Overall Business Goals 6.New Development • Win new deals • Competitive PPA biding • Buy on Life & Price • Optimize suppler choices 3.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 1.Operations Management • Lower the cost of asset operations • Reduce technical visits due to bundling & false alarms • Reduce costs from scheduling technician time and equipment 2.Asset Management • 18 month rolling budgets and forecasts • Avoid downtower rebuilds with increased uptower replacements • Reduce mobilization cost by bundling crane visits • Avoid downtime with inventory available 5.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 4.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 DigitalClone Life Models Suppliers
  11. 11. Thank you! 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 - Introducing DigitalClone Live

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