A new SETCON variable-speed gearbox has been successfully deployed at Petroleum Development Oman´s (PDO), marking another milestone in the deployment of high-efficiency drive technology for midstream oil and gas applications. The unit drives a 4.2 MW crude-oil booster pump supplied by Sulzer Pumps (UK) Ltd. and was installed on site by a local construction contractor.

Project Overview

Internal efficiency calculations confirm that the SETCON drive achieves energy savings of more than 376 kW constantly, compared to conventional geared fluid couplings deployed on parallel booster pump strings at the same site. Across the asset’s lifetime, this translates into a substantial reduction in operational expenditure and associated CO₂ emissions, while also improving the overall reliability of the booster station.

Key Technology Benefits

The commissioning of this unit further confirms the operational advantages of the SETCON variable-speed drive technology for oil and gas duty:

  • Best-in-class energy efficiency for variable-speed mechanical drives in this power class especially in part load operation.
  • Precise and stable speed control across the full 50%–100% operating range, enabling optimized process throughput.
  • No working oil required for power transmission, eliminating the slip losses inherent in fluid couplings and minimizing oil consumption.
  • Compact and reliable low voltage Frequency Converters in combination with robust Servos (ASM)
  • Low cooling requirements, a decisive advantage in hot climates with ambient temperatures reaching 55 °C
  • Soft-start capability, reducing electrical and mechanical stress on the driveline during start-up.
Outlook

This project set a reference that establishes SETCON as a leading solution for variable-speed pump drives across oil & gas, desalination, and power generation — applications where energy efficiency, reliability, and minimal auxiliary requirements are decisive.

Building on this success, further projects with similar configurations are already in the pipeline across the Middle East, covering both greenfield installations and the modernization of existing assets. Operators in the region are increasingly seeking drives that combine high efficiency with a compact footprint, simple low-voltage auxiliaries, and proven reliability under harsh ambient conditions — all areas where SETCON demonstrates clear advantages to the status quo.

Project Data at a Glance
  • Customer: Petroleum Development Oman (PDO) LLC
  • Pump OEM: Sulzer Pumps (UK) Ltd.
  • Location:  Sultanate of Oman
  • Application: Crude-oil Booster Pump Drive
  • Model: SETCON SC4A
  • Design Power: 4 400 kW
  • Design Speed: 4 800 rpm
  • Speed Range: 50 % – 100 %
  • Ambient Temperatures: 5 °C – 55 °C
  • Area Classification: Zone 2, Group IIB, T4
  • Soft-Start capable: yes
  • Commissioning: 2026
  • Energy Savings: >376 kW