SET GmbH and Sulzer Pumpen (Deutschland) GmbH are modernising the existing variable-speed drive of a 12 MW boiler feed pump by installing a SETCON gearbox.
Austria / Vienna [21.08.2026] – Wien Energie is modernising the boiler feed pump drive at the Simmering power station. An ageing BHS planetary gearbox and a 6.3 kV power converter cascade are being replaced by a highly innovative SETCON variable-speed gearbox. Sulzer Pumpen (Deutschland) GmbH is acting as the main contractor, responsible for project and site management, whilst the mechanical and electrical retrofitting is being carried out by SET GmbH in Klagenfurt. As part of this project, the 12.4 MW drive motor is also being overhauled by an external partner company.
The SETCON gearbox is characterised by latest variable-speed control method – a technology which, in addition to improving plant availability, also increases the plant’s overall efficiency. Furthermore, the technology impresses with its ideal utilisation of installation space through space-saving, robust low-voltage variable-frequency drive (LV-VFD) technology, thereby optimising maintenance and operational reliability.
Another key advantage of the retrofit is that the booster pump, main motor and boiler feed pump will continue to be used and remain in their current positions. The existing BHS planetary gearbox will be replaced by the variable-speed SETCON gearbox, whilst the lubrication and cooling systems will be retained as far as possible. This makes it possible to carry out the entire retrofit within the power station’s regular, short shutdown period.
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.
We are proud to announce the successful on-site commissioning of a SETCON variable speed drive at the Petroleum Development Oman (PDO) facility in Nahada, Sultanate of Oman.
The SETCON unit is integrated into the drive train of a Crude Oil Booster Pump operating in one of PDO’s key production sites. The pump is supplied by our valued OEM partner Sulzer Pumps, who has a long-standing track record of delivering reliable and high-performance solutions to the oil and gas industry.
Commissioning Highlights
The commissioning was completed smoothly and confirms the strong performance of our SETCON technology under the demanding conditions of crude oil production:
Excellent Efficiency – The SETCON drive delivers outstanding energy efficiency, directly contributing to a reduced energy footprint of the entire pumping application.
Excellent Control – Precise speed control ensures optimal adaptation to changing process conditions and enables stable, finely tuned pump operation.
High Availability – The robustness and proven reliability of SETCON technology ensure maximum uptime — a critical factor in continuous crude oil production.
Thanks to All Partners Involved
A project of this scale succeeds only through close collaboration among all stakeholders. Our sincere thanks go to:
the team at Petroleum Development Oman (PDO) for their trust and excellent cooperation on site,
our partner Sulzer Pumps for the reliable and professional collaboration as pump OEM,
and to the local service partners STS as well as our own project team, whose expertise and commitment made this successful commissioning possible.
We are delighted that the SETCON drive is now reliably contributing to efficient and safe crude oil production in Oman — and we look back with pride on the successful delivery of this project.
Interested in learning more about our SETCON solutions for oil & gas applications? Get in touch with us.
Dubai, UAE — SET Sustainable Energy Technologies (SET) is pleased to announce the establishment of a new subsidiary office in Dubai under the name SET Middle East L.L.C. – FZ, located at Meydan Free Zone. This strategic expansion marks a significant milestone in SET’s global growth and reinforces its long-term commitment to the Middle East and surrounding regions.
The new Dubai-based subsidiary has been founded with a clear focus on sales and service, enabling SET to support customers in the region more efficiently and effectively. By establishing a local presence, SET aims to strengthen customer relationships, improve response times, and deliver tailored solutions that meet the specific needs of regional markets.
“The Middle East is a key growth region for sustainable energy solutions,” said managing director Mr. Maximilian Hehenberger. “With SET Middle East L.L.C. – FZ, we are positioning ourselves closer to our customers and partners, ensuring higher service quality, stronger collaboration, and faster project execution.”
Meydan Free Zone was selected for its strategic location, world-class infrastructure, and business-friendly environment, providing an ideal platform for regional operations and future expansion.
Through this new subsidiary, SET Sustainable Energy Technologies reaffirms its mission to drive innovation, sustainability, and reliable variable speed drives, while continuing to deliver excellence to customers across the Middle East and beyond.
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)
