Our colleague Martin Fischer from SET is proudly presenting the #SETCON – our innovative, variable-speed gearbox – live at Flender Booth #9333 in Hall 9.
SETCON represents a new generation of high-efficiency mechanical power transmission, delivering flexibility, reliability, and energy savings for demanding industrial applications. ⚙️⚡
If you’re attending ADIPEC, make sure to stop by, meet Martin, and learn more about how SET is shaping the future of motion and drive technology.
We’re happy to announce that FLENDER & SET will be presenting the SETCON (a SET and FLENDER Collaboration) at ADIPEC 2025, taking place from November 3–6, 2025, in Abu Dhabi — one of the world’s leading energy exhibitions. You can find us at Booth 9333, Hall 9. 🔧 SETCON, our innovative variable drivetrain solution, enables energy-efficient, reliable, and digital operation across demanding industrial applications. Visit us to explore how SETCON technology is driving the transformation toward smart, sustainable, and flexible power transmission. We look forward to connecting with partners, clients, and industry leaders to discuss how we can shape the future of energy and motion together. 📍 Meet us at ADIPEC 2025 🗓️ 3–6 November 2025 📦 Flender Booth 9333, Hall 9
At the Duisburg-Huckingen gas-fired power plant (HKM / RWE), a recent retrofit of the Boiler Feed Pump (BFP) drive system has significantly outperformed expectations—delivering energy savings well above the guaranteed targets.
The modernization involved replacing a low-efficiency, geared variable-speed fluid coupling with a state-of-the-art SETCON SE6R electro-mechanical variable speed gearbox. This upgrade directly addressed the typical thermal losses associated with fluid couplings, resulting in a marked increase in system efficiency and long-term operational reliability.
The new drive system powers a 5.7 MW Boiler Feed Pump through a planetary gear stage, controlled by low-voltage Servo motors that precisely regulate the gearbox output torque, while reusing existing constant running Main Motor. Unlike fluid couplings—which suffer from increased losses when operating below full load—the SETCON gearbox maintains high and consistent efficiency across the entire load range. Additionally, the SETCON system is optimized for footprint compatibility. It shares the same footprint as the replaced geared variable-speed fluid coupling, utilizing existing anchor points and eliminating the need for any foundation modifications. This significantly reduced downtime during installation. Furthermore, the Booster Pump required no modifications and continues to operate at a constant speed using the existing Main Motor.
Independent measurements conducted by RWE Generation SE confirmed that the SETCON system saves over 1.3 MW on average within the plant’s defined operating conditions—substantially outperforming the legacy setup.
This successful retrofit not only demonstrates the technical and economic advantages of SETCON, but also establishes a proven reference project that can serve as a model for future upgrades in similar applications.
The Duisburg-Huckingen gas-fired power plant, with a net unit output of 2×303 MW, is part of Hüttenwerke Krupp Mannesmann GmbH (HKM)—one of Germany’s leading steel producers, with an annual output of approximately four million tons. The site’s energy supply is managed in partnership with RWE Generation SE (RWE), an international energy company strongly focused on emission reduction targets. RWE Generation is well known for promoting the sustainable transformation of the power generation sector.
The SETCON variable-speed gearbox, developed by the Austrian company SET Sustainable Energy Technologies GmbH, is a proven solution for retrofit projects in power plants and refineries that aim to improve energy efficiency without a complete system overhaul. Thanks to its compact frequency converter and space-optimized gearbox design, SETCON is particularly well suited for upgrading existing systems while offering high system availability.
The SETCON variable speed gearbox offers an ideal replacement for outdated variable speed fluid couplings. Thanks to its matching footprint, drivetrain downtime can be minimized to just 14–20 days during installation. Additionally, the existing main motor and lube oil cooler can be reused, helping to significantly reduce overall CAPEX.
👉 Check out our latests video below for more information:
In modernization of large rotating equipment, one recurring challenge stands out: how to improve performance without adding unnecessary complexity? Although medium-voltage variable frequency drives ( MV-VFD ) were the default, they often led to substantial infrastructure extension requirements, heat management issues, and high maintenance demands.
Meanwhile, SET Sustainable Energy Technologies GmbHengineering teams believe efficiency should not be delivered with extra complications. That is why SETCON variable speed gearbox is becoming the technology of choice. With its compact low-voltage electronics, energy regeneration capabilities, and proven efficiency up to 97%, it offers a more streamlined path forward — the technically reliable and operationally simpler alternative. In this article, we explore why more and more clients are choosing SETCON as the smarter solution for retrofits.
Simpler Design, Lower Installation Requirements
Packaging size plays a crucial role in choice of a variable speed drive. Especially when a plant faces limitations of the existing spaces such as e-rooms. Large sizing of Medium-Voltage VFDs themselves (see grey zone at point 3 in the scheme below) may cause extra installation expenses for expansion of storage rooms. MV-VFDs demand bulky transformers (see gray zone at point 2 in the scheme) or integrated ones, complex safety measures, and specifically trained staff to handle the high-voltage electronics. This adds costs, implementation burden, and maintenance complexity.
Additionally, the choice of MV-VFDs leads to unavoidable modifications of the existing infrastructure in order to fit the new operating conditions. The new isolation criteria necessitate the installation of a new Main Motor when a MV-VFD is implemented. Furthermore, if a booster pump is in operation (connected to exchanged Main Motor) an additional Pony Motor is required, to maintain the constant input speed.
✔ SETCON, by contrast, uses low-voltage electrical components – standardized Frequency Converters and Control Cabinet (see point 2 in the scheme). The compact design minimizes space requirements and simplifies installation. Plus, in case of availability of a low-voltage supply source, the need of a transformer eliminates completely.
✔As well, SETCON allows reuse of the existing constant-speed Main Motor (see point 1 in the scheme). The variable speed gearbox is adjusted to the operating conditions of the existing machinery, which significantly saves installation time and investments.
✔Are you requiring a new Main Motor anyway? => You are still winning with SETCON. Thanks to the 20% power from SETCON Servo motors (see them in orange colour, point 1 in the scheme), a new Main Motor can be supplied in a smaller size for new business projects – 80% of total output power.
SETCON Gearbox vs MV-VFD: Space Requirements
Heat & Energy Losses into Built-In Power Regeneration
MV-VFD systems inherently incur heat emissions, requiring constant large-scale AC room cooling systems or additional water supply to maintain cabinets’ operation.
✔ SETCON profits from its combined electro-mechanical design. Only 20% of the driven power goes through its air-cooled low-voltage Frequency Converters which leads to much lower losses in the cabinets.
✔From the mechanical side, SETCON Servos, connected to a planetary gear stage, function as generators in partial loads, feeding excess energy back into the grid. This mode minimizes overall power consumption and operational expense. The gearbox offers up to 97% overall efficiency. Read more interesting facts about SETCON Planetary gear stage.
Low-Voltage Electronics of SETCON Variable Speed Gearbox
Smooth Maintenance & Serviceability
Diving into the safety of working environment, another critical advantage of SETCON variable speed gearbox is worth mentioning — serviceability.
MV VFDs require maintenance by highly trained, certified technicians due to high voltage hazards. A typical MV system demands monthly inspections, stringent lock out/tag out procedures, and annual overhaul by factory authorized specialists to ensure insulation integrity and safe operation.
✔ In contrast, SETCON contains familiar low-voltage architecture in Frequency Converters and Servo motors, allowing routine tasks to be performed by local maintenance teams after basic trainings. This dramatically reduces service response time, reliance on external contractors, and associated maintenance costs.
✔ SET notes as well the wide availability of the spare parts for the LV system. SETCON design includes standardized components from well-known suppliers.
🎯 Final Takeaway
SETCON outperforms MV-VFDs by:
delivering equivalent or higher energy efficiency,
eliminating complexity of electrical infrastructure,
reducing cooling requirements,
adapting to the existing infrastructure & minimizing modifications,
enabling energy regeneration, and
simplifying maintenance.
For operators seeking smooth, reliable, and cost-effective Drive Train modernization, SETCON is a compelling electro-mechanical alternative to medium-voltage VFDs — delivering highly competitive performance with long-term guarantees.
Below you can find a typical efficiency comparison between SETCON variable speed gearbox and MV-VFD with gearbox for a boiler feed pump application:
Rated Power: 6000 kW
Rated Speed: 5000 rpm
Speed Range: 50% - 100%
Operating time: 8500 h/year
Load distribution: see blue histogram
Average savings: 1400 MWh/year
SETCON Gearbox vs MV-VFD: Annual Efficiency Comparison
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.
⚡ 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)
On April 24–26, join SET Sustainable Energy Technologiesat the ENPRO INC. booth (representative in Turkey). We are happy to meet you – Hall 1, Booth C09 – at the 29th International Energy and Environment Fair and Conference (#ICCI2025) in Istanbul.
At the foreground of our showcase is SETCON – advanced variable speed gearbox, designed to meet any demanding requirements at a power plant, refinery, or other industrial facilities.
Why SETCON?
✔️ It is an electro-mechanical variable speed gearbox designed to control the speed of large pumps and compressors with the rated power 3–15 MW. SETCON provides a combination of compact packaging, flexible DBSE & offset, and high reliability. These and many other advantages make SETCON to stand out as a premier choice for both – new business projects and retrofits.
Read more about what industries may gain from choosing SETCON as a reliable solution for modernization: SET article.
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.
