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© 2016 Sentient Science Corporation – Confidential & Proprietary
Agenda:
1. Introductions
2. Sentient Science Overview and...
SentientScienceCorp.-Proprietary/PrivateLevel1
Presenters:
Natalie Hils – Sentient
Manager of Revenue Marketing
nhils@sent...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Sentient Science Overview – Core Goals, IP, and Industrie...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Sentient Science Current Approach to Gearbox/Bearing Mode...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Sentient Science Overview – DigitalClone® Live Software f...
© 2016 Sentient Science Corporation – Confidential & Proprietary
GE 1.5MW wind turbines have experienced premature failure...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas Extra Life Technology Upgrades:
1.1 Case carburized ring gear – Be...
SentientScienceCorp.-Proprietary/PrivateLevel1
DigitalClone Fatigue Life Simulations
Procedure, assumptions and technical ...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Upgrades - Summary
Moventas GE 1.5 Extra...
SentientScienceCorp.-Proprietary/PrivateLevel1
Legacy Gearbox vs. Moventas PLH-1100 Critical Locations:
Moventas GE 1.5 Ex...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #1: New Bearing Materials
for High Speed Shaft Bearings...
SentientScienceCorp.-Proprietary/PrivateLevel1
MnS + Oxide
MnS + Oxide
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life...
SentientScienceCorp.-Proprietary/PrivateLevel1
62 62 62 62 62 62
59
56
51
47 47 47 46 47 47
60
62 62 62 62
61 61 61 61 61
...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
• Sen...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #2: Integrated Planet Gear
Bearings
Moventas GE 1.5 Ext...
SentientScienceCorp.-Proprietary/PrivateLevel1
Component Supplier A, HRC Supplier B, HRC
Races 61 60
Roller 61 60
MnS+Oxid...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #2: Legacy Planet Gear Bearings, 4-Row: Supplier A vs. ...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
Legacy GBX –
Supplier B...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #3: Case Carburized Ring Gear
Moventas GE 1.5 Extra Lif...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
Advanced Technology #3:...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
Legacy Gearbox
Ring gea...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #4: Improved Material
Specifications in Geared Componen...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
IMS pinion with inclusi...
SentientScienceCorp.-Proprietary/PrivateLevel1
Advanced Technology #5: Improved Tooth Surface
Roughness
Moventas GE 1.5 Ex...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
Ra = ...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Summary of Findings
• Sentient completed modeling and com...
© 2016 Sentient Science Corporation – Confidential & Proprietary
DigitalClone Recommendations
1. Sentient recommends to us...
SentientScienceCorp.-Proprietary/PrivateLevel1
Moventas GE 1.5 Extra Life Gearbox Upgrades - Summary
Moventas GE 1.5 Extra...
© 2016 Sentient Science Corporation – Confidential & Proprietary
1. Lowest Lifetime Cost-of-Ownership
• Upgrades reduce fu...
© 2016 Sentient Science Corporation – Confidential & Proprietary
Thank you!
Moventas GE 1.5 Extra Life Gearbox Achieves 4x...
SentientScienceCorp.-Proprietary/PrivateLevel1
Questions:
Natalie Hils – Sentient
Manager of Revenue Marketing
nhils@senti...
Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
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Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life

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The presentation outlines the upgrades Moventas made on the GE 1.5 Extra Life gearboxes.

Sentient Science validated the technology advances and life extension claims for the owner operator community and quantified the improvements in performance, durability and reliability.

The computational testing showed an overall life improvement by a factor of 4x. The life extension achieved was due to improvements made to the case carburized ring gear, integrated planet gear bearings, high speed stage bearings, tooth surface roughness, and material specification upgrades in both bearings and gears.

View a recording of this webinar at:
http://sentientscience.com/resource-library/videos/webinar-recordings/moventas-ge-1-5-extra-life-gearbox-achieves-4x-life/

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Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life

  1. 1. © 2016 Sentient Science Corporation – Confidential & Proprietary Agenda: 1. Introductions 2. Sentient Science Overview and Our Gearbox Partnerships 3. Moventas Extra Life Gearbox Overview – Why Develop and Core Upgrades 4. Technical Assessment of Moventas Upgrades and Life Extension Outcomes 5. Next Steps Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  2. 2. SentientScienceCorp.-Proprietary/PrivateLevel1 Presenters: Natalie Hils – Sentient Manager of Revenue Marketing nhils@sentientscience.com +1 716.807.8655 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Dr. Raja V. Pulikollu – Sentient Vice President of Implementations, Chief Materials Scientist rpulikollu@sentientscience.com +1 937.241.1144 Kari Huttunen - Moventas Director, Business Development North America Kari.Huttunen@moventas.com +1 503.477.3750
  3. 3. © 2016 Sentient Science Corporation – Confidential & Proprietary Sentient Science Overview – Core Goals, IP, and Industries A Trusted Third Party Enabling Life Extension of Rotating Equipment in two ways: 1. Computational Testing & Demand Management for Suppliers 2. Asset Management for Operators ☑ Life Extension☑ Root Causes☑ Predict Earlier Key Industries Served WIND ENERGY • 200,000 Global units • 20,000 assets under contract AEROSPACE • Rotorcraft, Fixed Wing, & Defense • (15 Years of R&D) RAIL • Wheel Rail Interface • Top of the Rail Friction Modifier and Lubricants
  4. 4. © 2016 Sentient Science Corporation – Confidential & Proprietary Sentient Science Current Approach to Gearbox/Bearing Modeling • Physical tests are unavoidable, but also expensive • Sentient offers it’s DigitalClone technology to provide a sophisticated virtual test Lab • Virtual test labs can support physical tests • Reduce costs • Go into physical testing with more confidence • DigitalClone can determine bearing and gear life based on: • Bearing material (Hardness, inclusions, etc) • Surface finish (grinded, polished, superfinished, etc.) • Lubrication properties (pressure and heat dependent viscosity, etc.) Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  5. 5. © 2016 Sentient Science Corporation – Confidential & Proprietary Sentient Science Overview – DigitalClone® Live Software for Operators User Interface Screenshots and Solutions for Operators – “Buy on Life”
  6. 6. © 2016 Sentient Science Corporation – Confidential & Proprietary GE 1.5MW wind turbines have experienced premature failures in the field before expected L10 20 year life Operators have experienced repeat failures of spare gearboxes that did not meet reliability expectations, and this has led to rising Major Component Repair and Replacement costs after end-of-warranty date. Moventas saw an opportunity to improve the design and components of known failure modes to reduce future failures, reduce O&M cost, and improve availability Moventas requested Sentient Science to provide third-party assessment of these key technology upgrades and quantify the life extension benefits for owner-operators Why Moventas Developed GE 1.5MW Extra Life Gearbox? Reduce Future Wind Turbine O&M costs and maintain high turbine availability
  7. 7. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas Extra Life Technology Upgrades: 1.1 Case carburized ring gear – Benchmark performance against industry standard to show the difference in component durability. 1.2 Integrated planet gear bearings - Prove that the 2-row arrangement is more robust than a 4-row arrangement, and benchmark the performance against a industry standard. 1.3 Improved tooth surface roughness – Prove that the surface roughness of Ra=0.3 will improve micropitting resistance compared with Ra=0.6. 1.4 Improved material specifications in geared components – Prove that new material specification is better than old one and provide benchmark analysis against industry standard 1.5 New material in bearings – Prove that White Etch resistant bearing is more resistant to white etching cracks than old design and industry standard. IMS Pinion Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  8. 8. SentientScienceCorp.-Proprietary/PrivateLevel1 DigitalClone Fatigue Life Simulations Procedure, assumptions and technical details Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Given: • GE 1.5 MW Turbine • Material samples provided by Moventas • Technical details on Moventas PLH-1100, PLH-1100-XL gearbox improvements Assumptions: • Material properties from Sentient’s Library as needed Procedure: • Loading analysis • Mixed elastohydrodynamic lubrication analysis • Lifing calculations • Post processing and interpretation of results • Sentient conducted in-detail material characterization analysis on Moventas provided bearing samples to obtain the following technical details, input to DigitalClone material and life prediction 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
  9. 9. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Upgrades - Summary Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Integrated Planet Gear Bearing Case Carburized Ring Gear New Bearing Materials for High Speed Stage Improved Tooth Surface Roughness In Gears Improved Gear Material Specifications = BRG 1 BRG 2 Black oxide layer + White Etch Resistant 60.8 61.2 61.9 61.2 60.8 56.7 58.7 53.8 52 52.3 48.7 46.8 47 44.3 40.8 40.5 30 35 40 45 50 55 60 65 0 500 1000 1500 2000 2500 3000 3500 Rockwell:HRC Depth: Microns 0.5Kg GE 1.5 Extra Life Gearbox Achieves 4x Life
  10. 10. SentientScienceCorp.-Proprietary/PrivateLevel1 Legacy Gearbox vs. Moventas PLH-1100 Critical Locations: Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Legacy Gearbox Moventas PLH 1100.2 Critical Components Normal Roller Load (N) Contact Stress (GPa) Normal Roller Load (N) Contact Stress (GPa) LSS_UW 30,887 1.470 37,433 1.264 LSS_DW 34,488 1.385 11,829 0.929 IMS_UW 15,969 0.965 14,451 1.074 IMS_DW 65,508 1.218 71,752 1.300 HSS_UW 29,961 1.174 33,225 1.167 HSS_DW 13,451 1.129 10,922 0.922 PGC 51,208 1.880 148,442 1.741 Highest Stress Lowest Stress Input Power Output Power Planet Gear Bearing and Planet Gear Low Speed Bearing Upwind Intermediate Speed Shaft Bearing Upwind High Speed Shaft Bearing Upwind Planetary Carrier Bearing Upwind Planetary Carrier Bearing Downwind Low Speed Bearing Downwind Intermediate Speed Shaft Bearing Downwind High Speed Shaft Bearing Downwind Sun Pinion Low Speed Shaft Gear Intermediate Speed Shaft Pinion High Speed Shaft Pinion Intermediate Speed Shaft Wheel • Sentient modeled the differences in GE1.5 MW Moventas PLH 1100.2 and Legacy Gearbox gearboxes • Overall, PLH-1100.2 bearings have relatively lower stresses than Legacy Gearbox • Moventas PLH-1100.2 integrated planet gear bearing design results in lower stresses
  11. 11. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #1: New Bearing Materials for High Speed Shaft Bearings (HSS) Black Oxide (BO) White Layer Etch Resistant Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  12. 12. SentientScienceCorp.-Proprietary/PrivateLevel1 MnS + Oxide MnS + Oxide Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Component Hardness, HRC Inner race 60 Outer race 61 Roller 61 Outer Race Case Core Case Core • Non-metallic MnS, Oxide and TiN inclusions are observed in the inner and outer raceway as-large-as (ALA) 35 and 50 µm, respectively • Inner raceway consists of Bainitic microstructure whereas Outer race has good martensitic microstructure • Roller is relatively clean and have good tempered martensitic microstructure • Black oxide thickness varies from 0.8 µm to 1.5 µm Inner Race Black oxide layer Advanced Technology #1: New Bearing Materials for HSS Bearing - BO
  13. 13. SentientScienceCorp.-Proprietary/PrivateLevel1 62 62 62 62 62 62 59 56 51 47 47 47 46 47 47 60 62 62 62 62 61 61 61 61 61 40 45 50 55 60 65 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Rockwell:HRC Depth: Microns White Etch Resistant Bearing IR OR RLR OxideCase Case Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Inner Race • IR is case hardened, whereas both OR and roller are through hardened. • IR case hardness is 62 and core is 47 HRC. • Average roughness of OR and roller is 62 and 61 HRC, respectively. • Presence of globular oxides, MnS and TiN inclusions ALA 10 µm were observed in Inner Race • High Cr % of 2.99% in the matrix Advanced Technology #1: New Bearing Materials for HSS Bearing – White Etch Resistant Bearing
  14. 14. © 2016 Sentient Science Corporation – Confidential & Proprietary Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life • Sentient conducted total 1,000 contact fatigue life simulations at 1.6 MW nominal torque and speed to predict the dominant damage mode and life - Pitting/spalling/wear • PLH 1100.2 XL HSS bearings have relatively lower contact stresses • White Etch Resistant and BO material quality is superior and have additional protection in the form of black oxide coating • DigitalClone predicts both White Etch Resistant and BO bearings to meet L10 life of 20 years. • However, BO predicted to have 3% probability of failure (POF) in less 20 years due to non-metallic inclusions. BO bearing predicted to have relatively lower life under high torque/uprate conditions • White Etch Resistant is superior in protection against white etch cracking resulting from heat treatment and improved microstructure • Sentient recommends to use White Etch Resistant bearing at HSS and HSIS bearing locations to avoid axial cracking RVE Size: 2.45mm by 1.57 mm No. of grains: 11,646 Bearing Contact surface Advanced Technology #1: New Bearing Materials White Etch Resistant and BO HSS Bearings Fatigue Life Simulation Results & Recommendations Bearing Type L10-Fatigue Life , years Contact stress, GPa HSS_White Etch Resistant 20 1.2 (UW-side) HSS_BO 20 1.2 (UW-side)
  15. 15. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #2: Integrated Planet Gear Bearings Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  16. 16. SentientScienceCorp.-Proprietary/PrivateLevel1 Component Supplier A, HRC Supplier B, HRC Races 61 60 Roller 61 60 MnS+Oxide Case Core Case Core Supplier A Supplier B Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life • Supplier A: Good hardness, Tempered martensitic microstructure with slight carbide banding and non-metallic inclusions as large as 10 µm • Supplier B: Good hardness, Bainitic microstructure, slight carbide banding, and non-metallic inclusions as large as 30 µm Advanced Technology #2: Integrated Planet Gear Bearings, 2-Row: Supplier A vs Supplier B MnS+TiN+Oxide Case Core
  17. 17. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #2: Legacy Planet Gear Bearings, 4-Row: Supplier A vs. Supplier B Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Supplier B Case Core Inclusion • Supplier A: Good hardness, tempered martensitic microstructure, carbide banding and non-metallic inclusions as large as 50 µm • Supplier B: Good hardness, Bainitic microstructure and non-metallic inclusions as large as 50 µm Case Core Mulit-phase inclusion Butterfly formation Supplier A Component Supplier A, HRC Supplier B, HRC Races 63 61 Roller 62 61
  18. 18. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Legacy GBX – Supplier B PLH-Supplier B Legacy Gearbox – Supplier A PLH-Supplier A • Sentient conducted 2000 fatigue life simulations to compare PLH1100 planet bearing with Legacy gearbox • DigitalClone fatigue life simulations predicted: • Highest fatigue life of PLH 1100 -XL-A bearing due to clean material quality and relatively lower contact stress • Fatigue life of PLH 1100 XL- B is higher than Legacy Gearbox due to lower contact stress and better material quality • Legacy gearbox planet shaft bearing fatigue lives are lower as they experience higher contact stresses and have lower material quality • The material quality difference between Bearing A MVS and Legacy is more significant than Bearing B, hence the huge difference in life Advanced Technology #2: Integrated Planet Gear Bearings PLH 1100 and Legacy Gearbox Bearing A&B Fatigue Life Simulation Results Case Study Max Contact Pressure (MPa) L10 rev L50 rev L90 rev Life Improvement PLH 1100_XL – A 1741 2.67E+09 1.31E+11 1.57E+12 216x PLH 1100_XL - B 1741 3.18E+08 5.60E+09 3.48E+10 26x Legacy - A 1880 3.78E+07 8.36E+08 6.01E+09 4x Legacy - B 1880 1.05E+07 1.35E+09 2.97E+10 1x
  19. 19. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #3: Case Carburized Ring Gear Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  20. 20. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Advanced Technology #3: Case Carburized Ring Gear Legacy Gearbox Ring Gear Material Quality 59 49 38 33 31 32 35 33 35 35 34 35 33 32 34 28 31 33 30 31 0 10 20 30 40 50 60 70 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Rockwell:HRC Depth: Microns Ring Gear Max Hardness: 59 HRC Min Hardness: 28 HRC • Ring gear is case carburized with max. surface hardness of 59 HRC and min. hardness of 28 HRC. • Case depth is 100µm • MnS, Tin and Oxide inclusions as large as 40 µm • Ring gear is case hardened and contains intergranular Cracks, Nitrided layer on surface, Fe3N grain boundary networks in the microstructure. These abnormal microstructure features lead to early crack nucleation and premature failures Contact surface Indents MnS inclusion Tri-phase inclusions
  21. 21. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Legacy Gearbox Ring gear Max Contact Pressure Pmax (MPa) L10, cyc L50, cyc L90, cyc PLH-1100.2 1371 20 years life ( based on clean material quality and no serial defects) Legacy Gearbox 1371 1.60E+07 6.80E+08 7.42E+09 • Sentient conducted a total of 1000 contact and bending simulations to predict the effect of case carburization on fatigue life • PLH 1100 XL ring gear have L10 fatigue life of 20 years based on assumption of clean material quality and no serial defects • Legacy Gearbox ring gear with poor material quality predicted to have life less than 7 years of L10 fatigue life Advanced Technology #3: Case Carburized Ring Gear PLH 1100 XL and Legacy Gearbox– Ring Gear Fatigue Life Simulation Results & Recommendations
  22. 22. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #4: Improved Material Specifications in Geared Components Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  23. 23. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life IMS pinion with inclusions IMS pinion Max Contact Pressure (MPa) L10, cyc L50, cyc L90, cyc With no inclusions 1330 20 years life ( based on clean material quality) With inclusions 1330 5.64E+06 9.75E+08 2.60E+10 • Sentient conducted contact fatigue life simulations to study the impact of non-metallic inclusions on IMS pinion fatigue lfie • PLH 1100.2 IMS pinion with no presence of detrimental inclusions is predicted to meet design L10 life of 20 years based on clean material quality and no serial defects • PLH 1100.2 with detrimental inclusions (ALA 150 µ) predicted to have L10 fatigue life of less than 5 years • It is recommended to use IMS pinion with martensitic microstructure with non-metallic MnS inclusions of size ALA <30µm and lower inclusion density for superior fatigue life Advanced Technology #4: Improved Material Specifications PLH 1100 IMS Pinion – Effect of Inclusions Fatigue Life Simulation Results & Recommendations
  24. 24. SentientScienceCorp.-Proprietary/PrivateLevel1 Advanced Technology #5: Improved Tooth Surface Roughness Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  25. 25. © 2016 Sentient Science Corporation – Confidential & Proprietary Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Ra = 0.3 Ra = 0.01 Ra = 0.6 Sun Pinion with Ra, µm Pmax (MPa) L10, cyc L50, cyc L90, cyc Life Factor 0.01 1781 9.08E+06 5.24E+07 6.67E+08 2.9x 0.3 1781 6.89E+06 3.75E+07 2.51E+08 2.2x 0.6 1781 3.10E+06 2.45E+07 1.77E+08 1x PLH 1100 XL –Sun Pinion Fatigue Life Simulations and Recommendations • Sentient conducted RCF simulations to predict the effect of surface finish on Sun Pinion fatigue life • Compared to Ra of 0.6 µm, Sun Pinion with 0.3 µm has a significant increase in L10 fatigue life (by a factor of 2.2x) • Increase in RCF L10 life (factor of 2.9x) with superfinish (Ra: 0.01 µm) • It is recommended to have Ra of 0.3 µm as a minimum surface finish specification Mixed-EHL pressure profiles for progressively smoother surface roughness Ra: 0.01µmRa: 0.2µmRa: 0.3µmRa: 0.6µm Advanced Technology #5: Improved Tooth Surface Roughness
  26. 26. © 2016 Sentient Science Corporation – Confidential & Proprietary Summary of Findings • Sentient completed modeling and comparison of PLH 1100, XL and Legacy Gearbox performance considering design, manufacturing, materials, and loading conditions. • Overall, PLH-1100 bearings have relatively lower stresses than Legacy Gearbox • PLH-1100 integrated planet gear bearing design results in 8% lower contact stresses • XL gearbox predicted to meet design L10 life of 20 years due to overall improvements in using advanced bearings, case carburized ring gear, better surface finish and clean martensitic microstructure with no presence of detrimental inclusions • Compared to Black Oxide (BO) bearing, White Etch Resistant bearing is superior in protection against white etch cracking resulting from heat treatment and improved microstructure • XL gearbox improvements can be reused in Moventas future gearbox designs, rebuilds and uptower repair services Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  27. 27. © 2016 Sentient Science Corporation – Confidential & Proprietary DigitalClone Recommendations 1. Sentient recommends to use White etch resistant case carburized bearing with high Cr-content in XL gearbox HSS and HSIS bearing locations 2. Black oxide and case carburized integrated planet gear bearings with retained austenite of 20-25% is recommended 3. For ring gear, case carburized martensitic microstructure with a case depth of about 1500 µm and case hardness of >60 HRC is recommended 4. The following microstructural features need to be avoided or reduced for better fatigue performance 1. Needle-like non-metallic MnS and metallic TiN inclusions of size >30µm and higher inclusion density 2. Carbide banding 3. Oxide/intergranular oxidation sites 4. Grain coarsening and de-carburization layer 5. It is recommended to have Ra of 0.3 µm as a minimum surface finish specifications to reduce asperity interactions and increase in XL gears and pinions RCF life Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  28. 28. SentientScienceCorp.-Proprietary/PrivateLevel1 Moventas GE 1.5 Extra Life Gearbox Upgrades - Summary Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Integrated Planet Gear Bearing Case Carburized Ring Gear New Bearing Materials for High Speed Stage Improved Tooth Surface Roughness In Gears Improved Gear Material Specifications = BRG 1 BRG 2 Black oxide layer + White Etch Resistant 60.8 61.2 61.9 61.2 60.8 56.7 58.7 53.8 52 52.3 48.7 46.8 47 44.3 40.8 40.5 30 35 40 45 50 55 60 65 0 500 1000 1500 2000 2500 3000 3500 Rockwell:HRC Depth: Microns 0.5Kg GE 1.5 Extra Life Gearbox Achieves 4x Life
  29. 29. © 2016 Sentient Science Corporation – Confidential & Proprietary 1. Lowest Lifetime Cost-of-Ownership • Upgrades reduce future repeat failures and O&M costs after end-of-warranty • Condition Monitoring 24/7 to follow up the health of your gearbox • Excellent up-tower serviceability 2. Lowest Risk • The strongest planetary stage featuring case carburized ring gear & planet wheels and integrated planet gear bearings with more than 15 years proven track record . • Industry-leading 5 year warranty to minimize risk due to Moventas end-to-end quality control and manufacturing processes 3. Life Extension Revenue for GE 1.5MW • Upgrades enable operators to implement life extension of wind farms to 25-30+ years, so gearbox continues to operate and maximize availability Benefits of Moventas GE 1.5MW Extra Life Gearbox Moventas Benefits can be Confirmed on Your Sites with DigitalClone Live
  30. 30. © 2016 Sentient Science Corporation – Confidential & Proprietary Thank you! Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life
  31. 31. SentientScienceCorp.-Proprietary/PrivateLevel1 Questions: Natalie Hils – Sentient Manager of Revenue Marketing nhils@sentientscience.com +1 716.807.8655 Moventas GE 1.5 Extra Life Gearbox Achieves 4x Life Dr. Raja V. Pulikollu – Sentient Vice President of Implementations, Chief Materials Scientist rpulikollu@sentientscience.com +1 937.241.1144 Kari Huttunen - Moventas Director, Business Development North America Kari.Huttunen@moventas.com +1 503.477.3750

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