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)
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.
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.
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.
SET received the »TD | ICT | EBS« 2024 award from the Carinthian Economic Development Fund for Innovative Technological Services.
SETCON variable speed drive was especially distinguished for its energy-saving performance. SET technologies were remarked as the improved, highly competitive products with strong future viability. With SETCON adaptive speed control, customers can operate even more safely and efficiently.
SET (Sustainable Energy Technologies) GmbH is delighted to announce the receipt of an order from the international energy company RWE Generation SE. The project will be implemented at the HKM thermal power plant Duisburg-Huckingen, Germany. It involves the replacement of an existing Voith R17 KGS hydro-dynamic geared coupling with the highly efficient SETCON® – electro-mechanical variable speed gearbox.
With a rated power of 5 750 kW and a rated output speed of 6 282 rpm, SETCON® is perfectly suited to meet on-site conditions, due to the matching gearbox footprint, which reduces implementation time and effort substantially. Furthermore, it will deliver significant energy savings compared to the status quo, with an average energy saving of more than 1 000 kW continuously.
In addition to the immediate benefits of increased efficiency, this project has the potential to lead to a follow-up order from RWE after the successful operation of this first SETCON® unit. This represents a major step forward in the efforts of SET GmbH together with RWE to reduce energy consumption and to promote sustainable practices in the power generation industry.
Energy efficiency is critical as it minimizes the amount of energy required, leading to lower energy costs, reduced greenhouse gas emissions, and improved energy security. Most recent investigations also confirm that energy efficiency is one of the most powerful methods for reducing energy-related emissions. Therefore, governments and organizations globally are enhancing energy efficiency through various policies and initiatives to set maximum energy efficiency levels for products and buildings. These initiatives have further promoted the utilization of energy-efficient technologies and practices, reducing energy consumption, emissions, and costs. SET GmbH is proud to be contributing to the shift towards energy efficiency and is confident that SETCON® technology will play an important role in meeting the growing demand for sustainable and environmentally relevant solutions.
About RWE RWE is leading the way to a green energy world. With an extensive investment and growth strategy, the company will expand its powerful, green generation capacity to 50 gigawatts internationally by 2030. RWE is investing more than €50 billion gross for this purpose in this decade. The portfolio is based on offshore and onshore wind, solar, hydrogen, batteries, biomass, and gas. RWE Supply & Trading provides tailored energy solutions for large customers. RWE has locations in the attractive markets of Europe, North America, and the Asia-Pacific region. The company is responsibly phasing out nuclear energy and coal. Government-mandated phaseout roadmaps have been defined for both energy sources. RWE employs around 19,000 people worldwide and has a clear target: to get to net zero by 2040. On its way there, the company has set itself ambitious targets for all activities that cause greenhouse gas emissions. The Science Based Targets initiative has confirmed that these emission reduction targets are in line with the Paris Agreement. Very much in the spirit of the company’s purpose: Our energy for a sustainable life. https://www.rwe.com/
About HKM GmbH Hüttenwerke Krupp Mannesmann GmbH has a core workforce of 3,000 employees and 191 trainees. The company produces 4.2 million tons of steel a year, which is processed into a wide range of everyday products, such as car bodies, washing machines and wind turbines. https://www.hkm.de/
About SETCON® SETCON® is SET’s proprietary electro-mechanical variable-speed gearbox designated to control the speed of large pumps and compressors. Compared to other variable-speed concepts, SETCON shows the highest overall efficiency and it is pioneering in terms of reliability and flexibility. Additionally, thanks to its matching footprint, SETCON is the ideal solution to replace low-efficient hydro-dynamic geared couplings.
SET successfully completed the 35-day test run periode at swb Erzeugung AG in Bremen, Germany with SETCON® SE6 recently . The expected energy savings compared to the replaced variable-speed gear coupling have been exceeded by far, so that the power plant unit can be operated even more efficiently in the future. This modernization project is a great success for everyone involved and guarantees efficient and reliable operation in the Mittelbüren power plant in the future.
In summary, the following project highlights result:
Energy savings of 12 815 MWh per year compared to the variable speed gear coupling
CO2 reduction of approx. 12 400 tons per year (corresponds to a CO2 consumption of 1 550 German residents)
Mechanical and electrical implementation and commissioning in 15 days
The foundations were not changed and the existing anchor points of the variable-speed gear coupling were adopted, thanks to the matching footprint
The existing lubricating oil cooler could continue to be used, the working oil cooler has been shut down due to lower the lower losses and reduced oil flow
Neither the pump nor the Main drive had to be repositioned on the existing foundation
Simple and safe integration into the existing control system (through SET’s control system simulation and customer acceptance in advance)
Located next to a steel works, the power plant unit converts blast furnace gas and converter gas into electricity.
SET has been awarded from swb Erzeugung AG & Co. KG to replace an existing hydraulic speed control coupling at the Mittelsbüren power plant in Bremen, Germany, with an energy-efficient SETCON® drive system. The aim of the project is to significantly modernise and improve the efficiency of the overall system, which will increase the total plant unit efficiency by 1%.
Using the variable speed SETCON® system to drive a boiler feed pump with a power of 6.5 MW allows swb Erzeugung AG & Co. KG to considerably reduce its electrical energy consumption and greenhouse gas emissions. In concrete terms, the SETCON® drive system will result in a saving of around 10,770 MWh and 12,400 tonnes of CO2[1] a year.
The old system is scheduled to be replaced in the third quarter of 2020 during the power plant’s periodic overhaul. As the SETCON® drive system has exactly the same footprint (series concept) as the existing hydraulic speed control coupling, the power plant will only have to be shut down for a short time to enable cost-efficient installation, no structural changes to the machine bed will be required. All other units such as the main motor, boiler feed pump and booster pump can continue to operate without modification following the overhaul.
SETCON® is an electro-mechanical variable speed drive system developed by SET that is perfect for replacing hydraulic couplings thanks to its high energy efficiency and outstanding retrofit capabilities. This innovative new drive concept is particularly well-suited for variable-speed operation of pumps, compressors and blowers with a drive power of > 4 MW and rated speeds of > 3,500 rpm, and the use of standard industrial components guarantees high system reliability and availability.
The Mittelsbüren power plant in Bremen is fired with blast furnace and converter gas taken from the neighbouring steel works, which reduces the latter’s CO2 emissions. The plant unit, which has an electrical output of 238 MW, is operated by swb Erzeugung AG & Co. KG, the division of the swb group responsible for conventional electricity and heat generation. The swb group has 2,145 employees and achieved a turnover of 1,361.1 million euros in 2018. The gas is taken from the furnaces in the steel works next door operated by ArcelorMittal Bremen, part of the world’s largest steel group ArcelorMittal, headquartered in Luxembourg.
[1] Blast furnace gas emission factor standard value = 0.965 tonnes CO2/MWh (LUGV)
November 18-20, 2015 saw further performance tests being conducted on the 4.1 MW SETCON® at Sulzer (Deutschland) Pumpen GmbH in Bruchsal/Germany. Similar to the tests at Elin Motoren GmbH in Weiz/Austria, the complete powertrain including boiler feed water pump was put through its paces here.
And once again the electro-mechanical differential system proved its excellent capabilities, efficiency, and reliability. All the customer’s requirements were met to PCK Raffinerie GmbH’s complete satisfaction and the professional cooperation between the companies involved was also demonstrated.
Local and international customers from the energy, industry, and oil and gas sectors also had the opportunity to gain an impression of the SETCON® benefits over these few days. All those who attended the event were impressed with its performance and agreed that the SETCON® is an ideal solution for efficient and reliable control.
In the latest issue of Sulzer Technical Review with the titel ” Wind Generators as Role Models” Sulzer Pumpen (Deutschland) GmbH presents SET GmbH and its electro-mechanical Differential System.
“Wind Generators as Role Models”
Dirk Küllmey, Klaus Löffler 04.11.2015…SET has been active in the field of wind power for more than 20 years, and it has developed wind generator gearboxes, which maintain the generated power at 50 Hz despite changing wind loads. Together with Sulzer, SET has now made use of this innovative gearbox concept on pumps… read the whole article: [Sulzer Technical Review]
SET’s electro-mechanical differential gear points the way ahead for the entire wind sector. In the interim this technology, DSgear-set, is also meeting with great interest in industry.
In the 4th quarter of 2014 Sulzer Pumps GmbH awarded SET GmbH a contract to install its electro-mechanical differential gear system (DSgear-set®) at the PCK refinery in Schwedt (Germany). By the 2nd quarter of 2015 the DSgear-set® will replace the existing direct drive system in order to meet future challenges in terms of sustainability and life cycle costs (LCC). SET’s electro-mechanical differential gear emerged as the best technology ahead of the competition in view of its speed variability range, efficiency, and robustness.
The DSgear-set® has to provide a rated power of 4,080 kW for a boiler feed-water pump, which is essential for the refinery processes at the site. In this flagship project the operating companies expect the DSgear-set® to ensure high cost savings, maximum reliability and Efficiency.Due to the excellent cooperation between the companies involved, follow-up projects are planned.
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