This Earth Day, SET Sustainable Energy Technologies proudly joined the global movement by switching off our lights for 60 seconds in March — a symbolic gesture to highlight that true sustainability comes from consistent, everyday actions.
For power plants, oil & gas, and other industries, every day presents an opportunity to cut energy consumption and lower emissions. That’s where SETCON variable speed gearbox makes a real difference.
Unmatched Efficiency: SETCON gearbox stands out as one of the most energy-efficient and sustainable solutions on the market,
Smart Energy Recovery: instead of wasting excess energy as heat, SETCON regenerates it back to the grid — reducing energy losses and cooling demands while maximizing efficiency.
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: theengineering advantages of the SETCON planetary stage are complemented with the gearbox’s minimized oil requirements (lubrication oil only).
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.
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.
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-voltageFrequency 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.
Within the upcoming World Sustainable Energy Days 2025, SET Sustainable Energy Technologies would like to highlight a crucial role of the clean energy and modernization of existing infrastructure.
SETCON® – variable speed gearbox
The transition to climate neutrality extends beyond building new renewable energy projects – the maximization the efficiency of existing equipment is also vitally necessary. As WSED 2025 focuses on a #competitive, #collective, and #climate_neutral future, we draw attention to enhancing retrofits for the operating power plants.
🔶 SETCON, state-of-the-art electro-mechanical variable-speed gearbox, is designed to optimize the performance by exchanging existing drives in thermal power plants. Instead of costly and time-consuming overhauls, the electro-mechanical gearbox upgrades power plant’s machinery in frames of a remaining foundation, ensuring smoother maintenance, lower operational costs, and a faster return on investment (ROI).
❔ How does SETCON contribute to a climate-neutral future?
Increases energy efficiency by up to 97%
Lowers CO₂ emissions by regenerating excess energy and bring it back to the grid
Reduces environmental impact by eliminating working oil, therefore cutting losses and cooling requirements
Enables effective retrofits, avoiding major structural changes
Ensures long-term reliability
Europe’s power sector demands solutions that are both sustainable and economically feasible. SETCON has already been proving its performance in the region for years, optimizing Drive Trains with boiler feed pumps and other high-energy demanding applications.
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.
✓ 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 has already proven its reliability in retrofit projects, offering industries a smarter, future-oriented transformation: www.set-solutions.net/sample-project
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.
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.
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.
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.
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.
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
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…
