Test runs successfully completed at swb Erzeugung AG & CO KG

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)

Successful SETCON SE6 implementation at power plant Mittelsbüren

A few days ago, the SETCON SE6 system was successfully installed in the power plant Mittelbüren at swb Erzeugung AG & CO. KG in Bremen Germany. In just 14 days during the power plant revision, it was possible to completely replace the geared variable-speed coupling with the efficient SETCON drive.

Project highlights:

  • Efficiency increase of the drive up to 55% in partial load
  • No shifting of remaining units as Main drive, Main and Booster Pump was necessary
  • The existing installation space and anchoring points of the coupling have been used
  • Continued use of existing lubrication oil cooler (shutdown of working oil cooler)
  • Installation in less than 14 days (due to exact footprint)
  • > 12.400 t/year CO2 Emission reduction
  • > 10.770 MWh / year energy savings
For further Infomation, please open the brochure: Folder Retrofit Project _ swb

SET presents SETCON SE6

Exclusive first impressions of the new SETCON® SE6 series.

SETCON® SE6 is part of the SE family and was specially designed for highly demanding industrial applications. Many years of experience and the use of advanced design and analysis tools have led to this optimized variable-speed gearbox, which uses nothing but tried-and-tested standard mechanical and electronic components. This type has impressive optimized installation space and adaptable axial offset, which enables fast and efficient retrofitting or modernization of existing systems. SE6 also offers ultimate reliability and maximum efficiency for new installations, and as with all other SET products, it meets high European quality and design standards. SE6 is used for horizontally operated pumps and compressors up to a rated output power of 6 MW and a maximum output speed of 10.000 rpm. The electric drive (servos and low-voltage frequency converter) is selected on a project specific basis in accordance with customer needs and the required speed range.

SETCON® SE6 Test runs at SET in Klagenfurt

As part of the project with swb Erzeugung AG & Co. KG in Bremen, Germany, SETCON® SE6 test runs will take place at the test field in Klagenfurt from August this year.

  • Application: variable speed drive for a boiler feed pump
  • Type: SE6
  • Power: 6 500 kW
  • Speed: 4 500 rpm

In the upcoming test runs, the complete system will be extensively tested for lubrication, performance and functionality. The recently completed SETCON® test bench at SET provides ideal test conditions. The performance tests are supported by an automation test bench on which the control software and the interface to the higher-level control system are prepared and tested under realistic conditions.

New SETCON test bench at SET

A few weeks ago, SET’s new 3 MW SETCON test bench was finalized in the SET test / assembly hall in Klagenfurt, Austria. This test bench was adapted exactly to the high quality demands and needs of the SETCON series. Different gearbox sizes as well as output speeds of up to 15,000 rpm can be flexibly tested thanks to an adaptable intermediate gear stage. Partial lubrication tests of a SETCON transmission stage are currently taking place before a complete SETCON system is tested at the new test bench soon. As part of a customer event, the new test bench and a current customer project are to be presented in mid of August this year.

Retrofit order from swb Erzeugung AG

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)

further information:

Virtual Model Approach (VMA) – SETCON Technology

As a pioneer in electro-mechanical differential technology (SETCON®) for industrial applications, we are constantly striving to further improve and optimize our systems. We focus on the design, the calculation and the analysis of our systems in order to guarantee excellent results on our test benches and afterwards in the field. We use the latest and most advanced analysis tools that go far beyond industrial standards.

A recent study at the MES2018 conference in cooperation with the company AVL List GmbH from Graz / Austria shows which innovative way SET goes in its calculations. Under the slogan “Virtual Model Approach” virtual and highly dynamic models of the entire drive train are mapped. All environmental influences (e.g. mains fluctuations) and their effects on the SETCON® system are taken into account. This allows better than ever to eliminate design weaknesses at a very early stage of development and later ensure reliable and long-lasting operation of the drive.

Here you find the link to the publication: Development of industrial continuously variable electro-mechanical drivetrain system based on virtual model approach

SETCON® technology – 5 strong reasons

Fluctuating electricity and oil prices, stricter Eco-design guidelines, and stricter environmental regulations mean that there is a growing need for high-efficiency variable speed drives. Already today, more than 50% of all compressor and pump systems over 3MW driven power are speed controlled. Inspired by this progress, SET has developed a new and innovative drive technology called SETCON®. The system is characterized by:

  1. Highest energy efficiency (up to 97%)
  2. Robust and reliable design through the use of industrial standard components (multiple sourcing) and minimum number of e-components
  3. Wide range of application from large turbomachines (pumps, compressors, fans, blowers and turbines) up to variable speed processes of mills, conveyor belts or wind turbines
  4. Lowest life-cycle costs due to optimized system technology and reduced service requirements
  5. Footprint optimization of the gear unit for retrofit/upgrade projects to maintain existing infrastructure such as base plate, main drive or cooling system and to improve efficiency and process control