Event, ProductMay 7, 2025

Exciting News: Introducing New SETCON SD2.5

We are pleased to announce the launch of a new model of SETCON variable speed gearbox: the SETCON SD2.5. It is specifically designed for 2-pole Motors (ca. 3000 rpm) and allows a maximum output speed up to 3500 rpm.

The SETCON SD2.5 is a powerful and efficient solution, particularly well-suited for retrofit projects which include replacing variable speed turbo couplings, supporting up to 2.5 MW of output power.

We are pleased to announce the launch of a new model of SETCON variable speed gearbox: the SETCON SD2.5. It is specifically designed for 2-pole Motors (ca. 3000 rpm) and allows a maximum output speed up to 3500 rpm.
Key Features of the SETCON SD2.5:

⚡ Rated power: 2.5 MW
⚡ Input speed: 3000 rpm
⚡ Output speed: 3000 rpm (up to 3500 rpm possible)
⚡ Speed range: 70% – 100%

And even more advantages!

⚡ Single Servo / VFD configuration => very small cabinet size
⚡ Robust and easy to maintain due to low-voltage 690 V / 400 V VFD
⚡ Integrated Soft Start functionality of Main Motor
⚡ Integrated lube oil system

Why ideal for retrofit projects?

✔️ Allows up to 10% increase in power and speed without Main Motor renewal
✔️ Matching footprint with many variable speed turbo couplings
✔️ Highest energy efficiency on the market
✔️ Reuse of existing Main Motor (directly driven)

Join us in engineering a reliable future 👉 contact SET Sales team

ProductMarch 20, 2025

Long-Term Reliability, and how it’s guaranteed at Every Stage of SETCON Gearbox’s Life Cycle

Long-Term Reliability, and how it’s guaranteed at Every Stage of SETCON Gearbox’s Life Cycle

In the energy sector, reliability isn’t just an option — it’s a crucial requirement. Industries demand continuous and resilient performance of machinery to maintain plant operation, meet regulatory standards, and ensure safety. At SET, we understand these critical needs and have engineered the SETCON variable speed gearbox to exceed industries’ expectations for long-term reliability at every stage — from initial design to service & maintenance.

Design Phase – Trust & Compliance

SETCON gearbox is engineered with a focus on the performance durability. SET experts underline the importance to determine a safe and long-term operation of the machinery from the beginning. The gearbox design incorporates:

  • Trustworthy Suppliers: standardized components have been chosen by SET among trusted European suppliers and manufactured in accordance with global quality standards. This commitment ensures that every SETCON unit delivers consistent performance even under extreme conditions,
  • Top-Tier Servos & FCs: SETCON Servo Motors and Frequency Converters are supplied via long-standing cooperations with some of the world’s top-rated manufacturers in their field,
  • Electro-Mechanical System: the engineering advantages of the SETCON planetary stage are complemented with the gearbox’s minimized oil requirements (lubrication oil only).
SETCON gearbox. Set up Drive train
Set-up Drive Train with SETCON variable speed gearbox

Test Runs Phase – Efficiency & Validation

The SET’s in-house test bench simulates real-world conditions to ensure the operational stability, especially for ATEX applications. As well, both, water- and air-cooled, models of SETCON variable speed gearbox are performed at public test runs.

  • Energy Efficiency: the gearbox achieves efficiency up to 97% and maintains the rates even in partial loads.
SETCON gearbox at the SET in-house test bench
SET test bench with the water-cooled model of SETCON gearbox installed

Installation Phase – Adaptability & Simplicity

Limited space availability or small distance between the Main Motor and Driven Machine? SET has already gained experience in fitting the demanding requirements smoothly and timely.

  • Compact, Flexible Size: the gearbox’s design is offered in several modular options from 3 to 15 MW. Additionally, every sizing may be adapted individually for a seamless retrofit into existing infrastructure,
  • Fast integration: by maintaining the same footprint, SETCON minimizes downtime during installation. One of the references showcased the installation time of only 14 days.
SETCON Gearbox has been implemented on the Pump Skid at Sulzer in Leeds
Installation of the air-cooled model of SETCON variable speed gearbox

Operation Phase – Consistency & Durability

SETCON offers years of reliable operation to help industries fulfill not only #2030 sustainable development goals but also keep efficient performance till #2050 clean energy targets.

  • Comprehensible Service: low-voltage Frequency Converters and Control Cabinet contribute to the high immunity and durability over decades, ensuring reliable performance. Without the complexity of high-voltage maintenance, the service lays at the fingertips of on-site employees,
  • Thermal Management: with an integrated lubrication oil system and low cooling requirements, SETCON steadily maintains optimal operating temperatures, contributing to an extended service life and compatibility with a surrounding infrastructure,
  • Faster Return On Investment(ROI): SETCON offers larger savings and lower operational expenses over the lifecycle of the equipment in comparison to the other solutions in the energy market. Calculate your individual benefits: here.
SETCON gearbox in operation at a power plant
SETCON gearbox in operation at a power plant

ProductJanuary 22, 2025

Upgrade Your Efficiency: Retrofit with SETCON

In the race toward greater cost-effectiveness and sustainability, selecting the right drive system is essential for achieving maximum results. Unfortunately, many facilities still operate inefficient couplings. For example, hydro-dynamic variable-speed drives (HDVSD) face high losses due to the slip in the fluid system.

Need a modern solution? => SETCON
SETCON, the electro-mechanical variable-speed gearbox, is engineered to overcome these challenges, offering a cutting-edge alternative with measurable advantages:

✓  No working oil => Lower Cooling Requirements
SETCON operates with minimal cooling needs, thanks to its reduced oil demand.

✓  No heat losses => Power Reuse
SETCON achieves up to 97% efficiency, including partial load modes.

✓  No modifications of Drive Train => Minimal Downtime
Flexible configuration of SETCON gearbox integrates seamlessly into your current anchor points, ensuring quick commissioning and minimal disruption of operations.

✓  Limited Space => Compact LV Electronics
Small packaging size of Frequency Converters and Control Cabinet is designed to occupy restricted areas: https://www.linkedin.com/posts/set-sustainable-energy-technologies-gmbh

✓  Faster ROI
SETCON’s high efficiency ensures a quicker return on investment, making it an economically perfect choice for industries which prioritize long-term performance.

SETCON, the electro-mechanical variable-speed gearbox, is engineered to overcome these challenges, offering a cutting-edge alternative with measurable advantages

SETCON has already proven its reliability in retrofit projects, offering industries a smarter, future-oriented transformation: www.set-solutions.net/sample-project

Industry, ProductDecember 11, 2024

Reliability through the Eyes of SET Expert Team

When it comes to ensuring operational excellence, no one understands the importance of reliability better than those responsible for achieving it every day. Meet Franz, a valuable part of SET team for over 15 years. His expertise contributes to what makes SETCON variable speed gearbox a benchmark in safety and innovation.

When it comes to ensuring operational excellence, no one understands the importance of reliability better than those responsible for achieving it every day. Meet Franz, a valuable part of SET team for over 15 years. His expertise contributes to what makes SETCON variable speed gearbox a benchmark in safety and innovation. “Reliability isn’t just about preventing failures; it’s about building trust—trust within customers in technology that keeps operations running smoothly year after year,” Franz, SET Head of Mechanical Design, explains.

“Reliability isn’t just about preventing failures; it’s about building trust—trust within customers in technology that keeps operations running smoothly year after year,” – Franz, SET Head of Mechanical Design, explains.

He emphasizes that efficient and long term performance of such a high-power machine as SETCON gearbox is achieved through intensive team efforts in development. SET Sustainable Energy Technologies GmbH brings together specialists from multiple disciplines to deliver the products that achieve exceptional rates of efficiency.

Franz and his team are as well involved in SET’s supplier qualification and manufacturing coordination:

“We rely on standardized components sourced from trusted, well-known European partners. The production and optimization are constantly supervised by SET Quality Management. For me, this is important to see that all suppliers and our employees share our commitment to high quality principles,” – he adds.

For years, SET has been transforming energy markets with its dedication to engineering innovation and reliability. With SETCON variable speed gearbox, industries gain a solution backed by the track record of proven success.

Keep updated with the latest SET news: https://www.linkedin.com/company/set-sustainable-energy-technologies-gmbh

Product, ProjectOctober 17, 2024

Success in Motion: SETCON underwent FAT in Leeds

We are excited to announce the successful Factory Acceptance Test (FAT) of SETCON Variable Speed Gearbox at Sulzer‘s facility in Leeds (UK), in collaboration with PDO (Petroleum Development Oman)
Successful Factory Acceptance Test (FAT) of SETCON Variable Speed Gearbox at Sulzer's facility in Leeds (UK), in collaboration with PDO (Petroleum Development Oman)
Successful Factory Acceptance Test (FAT) of SETCON Variable Speed Gearbox at Sulzer's facility in Leeds (UK), in collaboration with PDO (Petroleum Development Oman)

As part of this comprehensive FAT, the SETCON gearbox underwent a full load test and advanced performance tests with the complete pump string, ensuring optimal performance and reliability for PDO’s critical operations in Oman.

This groundbreaking gearbox is designed to provide precise speed control, exceptional energy efficiency, integrated Soft-Start function and high reliability, making it a game-changer for industrial applications. The rigorous testing guarantees that the system is ready to deliver top-tier performance while significantly reducing energy consumption.

A big thank you to the teams at Sulzer, PDO, and all involved in making this milestone a success! Together, we are driving the future of sustainable industrial solutions.

Tested Model: SETCON SC4A (4.100 kW, 4.850 rpm)

Successful Factory Acceptance Test (FAT) of SETCON Variable Speed Gearbox at Sulzer's facility in Leeds (UK), in collaboration with PDO (Petroleum Development Oman)
Successful Factory Acceptance Test (FAT) of SETCON Variable Speed Gearbox at Sulzer's facility in Leeds (UK), in collaboration with PDO (Petroleum Development Oman)

ProductOctober 7, 2024

LV Electronics of SETCON: Reliable, Durable, and built with Proven Components

The SETCON variable speed gearbox is distinguished by its highly competitive low-voltage electrical components, including Frequency Converters and Control Cabinet. SETCON electronics are designed for maximum safety and immunity, ensuring robust performance even in the harshest ambient conditions.

·      What distinguishes SETCON Electronics from others?
SET Sustainable Energy Technologies GmbH implements standardized components from well-known, reliable suppliers — proven to deliver outstanding durability over decades of operation. This ensures SETCON technology consistently meets the highest standards of reliability, while also simplifying maintenance.

An added advantage of SETCON low-voltage electronics is that they require minimal specialized qualifications from on-site engineers for maintenance, making them easy to service. Unlike high-voltage systems, which often demand complex certifications, SETCON low-voltage solution allows quick, efficient upkeeps with lower operational overhead.

SETCON variable speed gearbox is distinguished by its highly competitive low-voltage electrical components, including Frequency Converters and Control Cabinet. SETCON electronics are designed for maximum safety and immunity, ensuring robust performance even in the harshest ambient conditions
Frequency Converters and Control Cabinet of SETCON variable speed gearbox

According to the industrial research, low-voltage electronics have demonstrated superior resilience to power surges, vibrations, and temperature fluctuations, making them particularly suitable for demanding environments like Oil & Gas plants. Additionally, these components benefit from longer operational life due to reduced wear and tear on insulation and connectors, commonly seen in high-voltage systems. This increases MTBF (mean time between failures), ensuring a longer service life with minimal disruptions.

SETCON compact packaging size of Frequency Converters and Control Cabinet is another key benefit. Despite their advanced capabilities, they are designed to occupy minimal space, streamlining the installation process in restricted areas, particularly beneficial for retrofits or offshore applications where space is a premium. This reduces the overall footprint and integrates easily into existing systems.

By combining this electrical reliability with the space-saving design (https://lnkd.in/dApSQsdt) and durability of SETCON mechanical systems, the variable speed gearbox continues to set the standard for reliability, safety, and ease of maintenance in the energy market.

Industry, ProductSeptember 24, 2024

Air-cooled SETCON: Game-Changer for Oil & Gas Industry

At hot and dry ambient conditions, SETCON Gearbox maintains highly efficient performance.
The air-cooled option of the SETCON variable speed gearbox provides low cooling requirements, as it operates without any water supply or working oil. Due to its innovative technology of power regeneration, SETCON gearbox stands out in the market.

Don’t miss the video to glance into the details:

More video content about the technology of the SETCON electro-mechanical gearbox at the SET Channel

ProductSeptember 5, 2024

SETCON – Ideal Solution for the Oil & Gas Applications

SETCON - Ideal Solution for the Oil & Gas and Offshore Sector
Tap picture to download

SETCON is a variable speed drive for pumps and compressors > 3 MW.
It shows one of the highest efficiency rates on the market (especially in partial load operation) and impresses with its low cooling requirements. The small low voltage electronic drive leads to an optimized installation space, making SETCON an ideal solution for offshore oil&gas applications.

The drive comes with an optional integrated lubrication system and is suitable for ambient temperatures > 55°C.
The minimized installation space including an offset gear stage makes it an ideal solution for Retrofit applications, replacing standard gearboxes, geared fluid couplings, gas/steam turbine drives and many more…

ProductJuly 26, 2024

Interesting Facts about SETCON Motors

Interesting facts about SETCON Electric Motors

Electric Motors have revolutionized the world of power and speed control, providing precise, robust, and outstanding performance across various industries. The Servos – 6-pole electric motors of the SETCON variable-speed gearbox, in particular, operate with strong results in the matter of energy efficiency and sustainability. The reliability of SETCON Servo Motors is based on both – their innovative development and centuries-old engineering heritage.

The state-of-art motors are one of the key reasons of the gearbox’s high energy savings. With the advanced Soft-Start technology, SETCON is able to operate in three modes:

  • supporting the safe, moderate start of the Main Motor of the Drive Train with minimal inrush current,
  • generating and redirecting extra energy for its sustainable reuse,
  • and upgrading the overall output power of the Main Motor.
SETCON variable speed gearbox. Interesting facts about electric motors
SETCON variable speed gearbox

The journey of electric motors began 190 years ago. The concept can be traced back to the early 19th century with the work of Thomas Davenport, who built the first commercially successful electric motor in 1834.

Further development of the electric motors was accompanied by the discovery of their reversibility. The inventions of Zenobe Gramme in 1873 and Frank Sprague in the 1880s fit the arising demand for energy savings and efficiency.

Check out how SETCON performs the energy regeneration to main supply systems nowadays: open SETCON Animation & control the speed of a pump at the partial load 50-74%. Energy efficiency is at your fingertips!

Continuous, meticulous research and experiments brought to life the application of various radical improvements. The inventions of such technologies as AC systems, permanent magnets, brushless commutators, sensors, and finally digitalization – all contributed to the modern success of electric motors and their high relevance for variable-speed applications.

Industry, Product, ProjectJune 4, 2024

Remarkable achievement of SET in our latest Oil & Gas project

Recently, SET showcased outstanding results during the internal Factory Acceptance Test (FAT) of SETCON variable speed gearbox, in collaboration with our valued customer from Oman.

The innovative SETCON SC4A, engineered to deliver variable speed to a 4.1 MW crude oil booster pump, has been designed to excel in hazardous environments and withstand ambient temperatures of up to 55°C. Its exceptional energy efficiency performance promises significant power savings and reduced CO2 emissions compared to conventional Variable Speed Drives (VSDs), offering substantial benefits to our customer.

SET showcased outstanding results during the internal Factory Acceptance Test (FAT) of SETCON variable speed gearbox, in collaboration with our valued customer from Oman. The innovative SETCON SC4A, engineered to deliver variable speed to a 4.1 MW crude oil booster pump, has been designed to excel in hazardous environments and withstand ambient temperatures of up to 55°C. Its exceptional energy efficiency performance promises significant power savings and reduced CO2 emissions compared to conventional Variable Speed Drives (VSDs), offering substantial benefits to our customer.
SET showcased outstanding results during the internal Factory Acceptance Test (FAT) of SETCON variable speed gearbox, in collaboration with our valued customer from Oman. The innovative SETCON SC4A, engineered to deliver variable speed to a 4.1 MW crude oil booster pump, has been designed to excel in hazardous environments and withstand ambient temperatures of up to 55°C. Its exceptional energy efficiency performance promises significant power savings and reduced CO2 emissions compared to conventional Variable Speed Drives (VSDs), offering substantial benefits to our customer.

Congratulations to the entire SET Sustainable Energy Technologies GmbH team on their remarkable achievement in contributing to our latest Oil & Gas project. We eagerly anticipate witnessing the deployment of this state-of-the-art SETCON gearbox at the customer’s site.

Follow SET on LinkedIn to stay updated: @set-sustainable-energy-technologies