In addition, to the high CO2 emission reduction, our recently implemented 6.5 MW SETCON – variable speed gearbox is saving up to 12 815 MWh energy per year, compared to the replaced hydro-dynamic gear coupling. This corresponds to an energy consumption of
a.) ~ 4 250 German households per year (3 012 kWh / year / household) or an energy production of a
b.) 4 MW wind mill with good wind conditions (3 000 full load hours)
Energy savings in comparison
Replacement of a hydro-dynamic gear coupling with a 6.5 MW by a SETCON SE6
According to the latest measurements the recently implemented SETCON SE6 – variable speed gearbox is saving up to 12 400 tons of CO2 per year, compared to the replaced hydro-dynamic gear coupling on-site.
This represents an average CO2 consumption of ~ 1 476 EU citizens per year (8,4 t/year – 2018) and contributes significantly to industrial decarbonisation.
A few days ago, the SETCON SE6 system was successfully installed in the power plant Mittelbüren at swb Erzeugung AG & CO. KG in Bremen Germany. In just 14 days during the power plant revision, it was possible to completely replace the geared variable-speed coupling with the efficient SETCON drive.
- Efficiency increase of the drive up to 55% in partial load
- No shifting of remaining units as Main drive, Main and Booster Pump was necessary
- The existing installation space and anchoring points of the coupling have been used
- Continued use of existing lubrication oil cooler (shutdown of working oil cooler)
- Installation in less than 14 days (due to exact footprint)
- > 12.400 t/year CO2 Emission reduction
- > 10.770 MWh / year energy savings
For further Infomation, please open the brochure: Folder Retrofit Project _ swb
Exclusive first impressions of the new SETCON® SE6 series.
SETCON® SE6 is part of the SE family and was specially designed for highly demanding industrial applications. Many years of experience and the use of advanced design and analysis tools have led to this optimized variable-speed gearbox, which uses nothing but tried-and-tested standard mechanical and electronic components. This type has impressive optimized installation space and adaptable axial offset, which enables fast and efficient retrofitting or modernization of existing systems. SE6 also offers ultimate reliability and maximum efficiency for new installations, and as with all other SET products, it meets high European quality and design standards. SE6 is used for horizontally operated pumps and compressors up to a rated output power of 6 MW and a maximum output speed of 10.000 rpm. The electric drive (servos and low-voltage frequency converter) is selected on a project specific basis in accordance with customer needs and the required speed range.
As part of the project with swb Erzeugung AG & Co. KG in Bremen, Germany, SETCON® SE6 test runs will take place at the test field in Klagenfurt from August this year.
- Application: variable speed drive for a boiler feed pump
- Type: SE6
- Power: 6 500 kW
- Speed: 4 500 rpm
In the upcoming test runs, the complete system will be extensively tested for lubrication, performance and functionality. The recently completed SETCON® test bench at SET provides ideal test conditions. The performance tests are supported by an automation test bench on which the control software and the interface to the higher-level control system are prepared and tested under realistic conditions.
A few weeks ago, SET’s new 3 MW SETCON test bench was finalized in the SET test / assembly hall in Klagenfurt, Austria. This test bench was adapted exactly to the high quality demands and needs of the SETCON series. Different gearbox sizes as well as output speeds of up to 15,000 rpm can be flexibly tested thanks to an adaptable intermediate gear stage. Partial lubrication tests of a SETCON transmission stage are currently taking place before a complete SETCON system is tested at the new test bench soon. As part of a customer event, the new test bench and a current customer project are to be presented in mid of August this year.
As a pioneer in electro-mechanical differential technology (SETCON®) for industrial applications, we are constantly striving to further improve and optimize our systems. We focus on the design, the calculation and the analysis of our systems in order to guarantee excellent results on our test benches and afterwards in the field. We use the latest and most advanced analysis tools that go far beyond industrial standards.
A recent study at the MES2018 conference in cooperation with the company AVL List GmbH from Graz / Austria shows which innovative way SET goes in its calculations. Under the slogan “Virtual Model Approach” virtual and highly dynamic models of the entire drive train are mapped. All environmental influences (e.g. mains fluctuations) and their effects on the SETCON® system are taken into account. This allows better than ever to eliminate design weaknesses at a very early stage of development and later ensure reliable and long-lasting operation of the drive.
Here you find the link to the publication: Development of industrial continuously variable electro-mechanical drivetrain system based on virtual model approach
Fluctuating electricity and oil prices, stricter Eco-design guidelines, and stricter environmental regulations mean that there is a growing need for high-efficiency variable speed drives. Already today, more than 50% of all compressor and pump systems over 3MW driven power are speed controlled. Inspired by this progress, SET has developed a new and innovative drive technology called SETCON®. The system is characterized by:
- Highest energy efficiency (up to 97%)
- Robust and reliable design through the use of industrial standard components (multiple sourcing) and minimum number of e-components
- Wide range of application from large turbomachines (pumps, compressors, fans, blowers and turbines) up to variable speed processes of mills, conveyor belts or wind turbines
- Lowest life-cycle costs due to optimized system technology and reduced service requirements
- Footprint optimization of the gear unit for retrofit/upgrade projects to maintain existing infrastructure such as base plate, main drive or cooling system and to improve efficiency and process control
For constructing new drive systems, SETCON represents the best solution for high energy savings and low investment costs. Due to the reduced package seize, lower oil volume/oil cooling, minor heat generation/air conditioning and pipework, the investments will be minimized.
Furthermore, the Main Drive can be downsized by up to 20% of total power rating, influencing total project costs positively.
For Retrofits SETCON can be implemented into existing drive systems without repositioning main components in most cases. By replacing e.g. a hydro-dynamic Coupling, the Main Drive as well as the Driven Machine remain in an original state. Both the mechanical and electrical interfaces are ideally matched to replace existing drives.
SETCON has the potential to boost both efficiency and performance and to ensure a sustainable and reliabel operation.