An industry case study that details Sentient’s DigitalClone® Lifing evaluation on the impact of REWITEC®’s additive DuraGear® W100 application. Learn How: - To reduce your COE and take control of your wind assets pro forma - Lubrication additives effect the life of your wind turbine drivetrain - Surface finish extends gearbox life - To maximize asset value with lubrication upgrades View the Webinar at: http://sentientscience.com/resource-library/videos/assessing-impact-surface-treatment-solutions-extend-asset-life/

1. © 2016 Sentient Science Corporation – Confidential& Proprietary

2. © 2016 Sentient Science Corporation – Confidential& Proprietary
Energy
Wind 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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3. © 2016 Sentient Science Corporation – Confidential& Proprietary
Three Life Extension Services
1. DigitalClone®
o Materials-Based Computational
Testing (SaaS)
2. DigitalClone® Live for Operators
o For Life Extension of Gearboxes, Main
bearings, Pitch Bearings
3. DigitalClone® Live for Suppliers
o Interface Suppliers with Operators
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4. © 2016 Sentient Science Corporation – Confidential& Proprietary
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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5. © 2016 Sentient Science Corporation – Confidential& Proprietary
DigitalClone® How to Extend Life of Assets
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6. © 2016 Sentient Science Corporation – Confidential& Proprietary
Introducing DigitalClone® Live for Suppliers
With 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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7. © 2016 Sentient Science Corporation – Confidential& Proprietary
REWITEC® Engagement Summary
Business 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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8. © 2016 Sentient Science Corporation – Confidential& Proprietary
Sentient Science History
8
2001-2016
$25M in R&D Funding
From the world’s
largest operator of
heavy equipment
2010
NASA Validation
Of game changing
technology,
DigitalClone®
2014
Tibbett’s Award
White House honors
DigitalClone®
technology-
“decoding the
Material Genome”
April 2016
New Energy Pioneer Award
Michael Bloomberg
honors commercial
impact of DigitalClone®
technology in Sentient’s
1st Clean Energy market
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9. © 2016 Sentient Science Corporation – Confidential& Proprietary
Load Case
Weibull,
Life/Eta
Weibull,
Slope
300 HP Run-out Run-out
1021 HP 5.14E+07 1.72
1379 HP 1.26E+07 3.32
2042 HP 7.49E+06 3.84
1731 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 Validation
Example of Sentient Science’s Previous Surface Work
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48. © 2016 Sentient Science Corporation – Confidential& Proprietary
Technical Step #1: Transfer of Data and Material
REWITEC® 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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49. © 2016 Sentient Science Corporation – Confidential& Proprietary
• 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 & Material
REWITEC® Test Details for Bearings Roughness Input to DigitalClone® Simulation
FE-8 Test – Gear Oil
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50. © 2016 Sentient Science Corporation – Confidential& Proprietary
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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51. © 2016 Sentient Science Corporation – Confidential& Proprietary
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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52. © 2016 Sentient Science Corporation – Confidential& Proprietary
Technical Step #4: Mixed EHL Model
Assessing theImpactof Lubrication Solutionsto Extend AssetLife
Lubrication Testing & Surface Treatment
52

53. © 2016 Sentient Science Corporation – Confidential& Proprietary
Technical Step #5: DigitalClone® Life Simulation
Intermediate 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.
L50 Life
Operational Hrs.
L90 Life
Operational Hrs.
“As Is” 4,239.70 5.58E+05 1.66E+07
REWITEC®
“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.
L50 Life
Operational
Hrs.
L90 Life
Operational Hrs.
“As Is” 787.7 2,678.1 27,443.9
REWITEC®
“To Be”
1,405.0 9,928.8 66,809.7
Life
Improvement
1.8 3.7 2.4
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54. © 2016 Sentient Science Corporation – Confidential& Proprietary
Technical Step #6: Life Results
Winergy 4410.2 GBX Life Extension using DuraGear® W100
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55. © 2016 Sentient Science Corporation – Confidential& Proprietary
Executive Summary
Sentient 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 Fleet
o Apply on Vestas, Siemens, Acciona, Gamesa Turbines
o Main Bearing Life Extension
o OEMS and ISPS
o Insurance Companies
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