SET Sustainable Energy Technologies shares the recent European Commission’ s statements about tackling climate change. The need for low-CO2 production has never been greater than now.
“We saw the chaos and carnage of extreme weather… right across our Union. This is the reality of a boiling planet.” – As the European Commission President Ursula von der Leyen remarked in SOTEU speech this week, – “we shifted the climate agenda to being an economic one. This has given a clear sense of direction for investment and innovation… And we have already seen this growth strategy delivering in the short-term. Europe’s industry is showing every day that it is ready to power this transition. Proving that modernisation and decarbonisation can go hand in hand“.
Especially the energy industry is in desperate need of modernization. SET Sustainable Energy Technologies is continuously working on the leading edge of innovation in the drive technology field to contribute to a CO2-reduced energy transition and supply. Our vision is to revolutionize the market with our highly efficient and innovative SETCON variable-speed gearbox, devised based on 35 years of experience in the development of industrial drives.
Implementation of SETCON variable-speed gearbox increases the whole drive train efficiency and reduces downtime to an absolute minimum. A robust standardized gearbox design and outstanding durability of used low-voltage frequency drive technology with a MTBF of up to 60 years underlines this.
SET Sustainable Energy Technologies’ vision keeps aligned with the opinion of the EU majority, according to the recent European Commission report on climate change 2023. Three quarters (75%) of EU citizens agree that the innovative technology development is a natural step in tackling climate change. Consequently, this will make EU companies more competitive on the market.
Variable speed gearbox SETCON is valued as one of the most energy efficient drive thanks to its innovative mechanical power transmission and small, low-voltage (LV) electronic components. SETCON is an ideal solution for Driven Machines larger than 3 MW and a rated speed up to 15,000 rpm. With an energy efficiency rate up to 97% and outstanding performance in partial load, SETCON points the way ahead for a sustainable future.
Although the technology is very new and innovative, SETCON shows a good testing and performance track record of over 3 years already.
SETCON system is able to regenerate energy in partial load operation, instead of facing hydraulic losses, which in the end result in heat and corresponding cooling requirements. There are no equivalent technologies on the market with the same impressive performance by now.
SETCON allows to minimize power losses essentially. SET Servo motors feed back excess energy into the LV grid in a generator mode, and the energy will be reused by the Main Drive. Check the functionality of the SETCON gearbox: SET Interactive Animation.
Enormous amounts of energy are globally wasted, which seriously endangers our shared environment. A true energy efficiency revolution is needed, and SET works daily to make a positive contribution to this. We offer a wide range of services to our customers, including detailed calculation of economic efficiency, assessment of current situation and improvement analysis, optimization of customized SETCON concept and more.
Let’s make our world emission-free together, check SETCON advantages here: Folders.
SET is pleased to reveal that our Electrical Automation expert Marco Fister has concluded a positive assessment of the newest SET software version optimized for the latest Totally Integrated Automation Portal edition (TIA portal).
SET Sustainable Energy Technologies GmbH regularly and multiply undergoes examinations of any changes in the SET projects to ensure the exact implementation of our customers preferences.
The tests have been fulfilled on the innovative SET Automation Test Bench with a down-scaled model of the SETCON gearbox. The system is used to check the functionality of various configurations before the SET Main Test Bench launch. The included Control cabinet receives commands from the emulation of an industry’s DCS and, inter alia, sends back the real-time process indications of the SETCON electro-mechanical variable-speed gearbox. Sufficient pre-testing of the software ensures an optimal coordination of the interface between the SET PLC and the DCS and furthermore saves time for the implementation on-site.
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Well-known that SETCON gearbox consists of a differential planetary gear. The Planet carrier with three planets is connected to two Servo motors in order to adjust a variable output speed from 20% to 105%, with an overall efficiency of more than 99%. But how is it working?
The Planetary gear ensures the speed control at a Driven Machine (e.g., Pump or Compressor) and, additionally, regulate the torque in the entire drive train.
The planet carrier with three planets, is connected via additional gear stages with the two Servo motors operating at variable speeds with up to 2000 rpm, located on the top of the gearbox. By turning the planet carrier in the same direction than the sun gear (connected to the Driven Machine) the speed / power is increased, and the Servos add additional power to the system. The main power flow derives from the Main Motor (connected to the Ring gear) and is superimposed by the Servo power.
Additionally, the two Servos can “brake” the system with up to 20% of the system rated power by turning the planet carrier in the opposite direction of the sun gear. The generated energy (Servos work as generators) is fed back to the grid and is consumed by the Main Motor again. Unlike hydraulic systems, where this energy is converted into heat loss, the braking energy is used regeneratively. This results in very high system efficiencies in the partial load range. Watch Animation.
Important advantages of Planetary gears are the up to 3 times increased torque capacity per-unit-volume (compared to spur gears). This allows a superior compactness of the device.
These units are well-known for the exceedingly long service life. Higher stability and resistance to damage of planetary gears is kept thanks to multiple larger contact surfaces and uniform weight distribution in comparison to other gear types.
Planetary gears are applied by humans for centuries. Under one of the theories, a similar device was used by Ancient Greeks inside the Antikythera mechanism in the 2nd-3rd centuries BC to calculate the motion of celestial bodies and dates of astronomical events. Later, in XI century Arabian engineer Ibn Khalaf al-Muradi mentioned planetary gears in his instruction on clock designs.
Recently, SET upgraded its production facility in Klagenfurt, Austria, with a new extended lifting crane. Now Sustainable Energy Technologies areas of gearbox assembly and testing cooperate with much higher flexibility. SET goal is to optimize overall product delivery time.
“The new crane that we just installed raises the load capacity of SET manufacturing. I am happy that my team’s work gets faster and easier,” – Johann Kircher, the head of SET manufacturing and assembly, comments.
The modification increases SET production and testing volumes. This guarantees that customers will much more rapidly and efficiently gain control over their industry with the SETCON electro-mechanical variable-speed gearbox.
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Today, Sustainable Energy Technologies celebrates Intern Day and reminds to appreciate young generations of technical specialists. SET intern Vi Dong Tran comments how essential this opportunity is:
“Before, I did not have trust to myself, I was afraid not to understand my tasks, but SET team gives me self-confidence. SET taught me their innovative technologies, and now I find it very interesting to be involved in the process, to watch how an idea turns into the impressive machine – SETCON®”.
SET intern remarks that school students should be guided by an example of success:
“For us, it seems that there is a huge time gap for a career decision, but actually time flies so fast by. Therefore, it is so crucial to start my working way already now and in such a company as SET”.
Vi Dong Tran lives and studies in Austria:
“As a local, I am proud that this ground-breaking company SET represents Austria on international market. It is astonishing!”
Today SET team appreciates the culture of our customer Petroleum Development Oman (PDO) and tastes the Omani traditional dish – Mishkak – at our SET corporate event. SET Sustainable Energy Technologies GmbH admires the international background of our clients, partners, suppliers, and employees and promotes the cultural awareness.
Mishkak is grilled halal meat served on skewers. It is popular all over Oman as fast street food, especially during celebrations and holidays. And as we have experienced, the Mishkak cooking process is a people-bonding matter. Our team has had much fun grilling it together.
Our company SET Sustainable Energy Technologies GmbH is delighted to announce to be selected by Petroleum Development Oman (PDO) for the implementation of a SETCON electro-mechanical variable-speed gearbox for the Nahada-1 Booster Station at Fahud Plant in Oman.
In this project, Sulzer Ltd. will be responsible for the delivery of the complete new crude oil booster pump string, involving a high-efficient SETCON SC4A unit. Furthermore, the companies Arabian Industries Projects L.L.C. and PETROFAC E&C Oman L.L.C. have been awarded as main contractor and engineering subcontractor respectively
The SETCON unit itself has an output power capacity of app. 4.1 MW and output speed of app. 4,850 rpm. Furthermore, it is designed to operate at ambient outdoor temperature conditions ranging from 5°C to 60°C, with a lube oil system referring to API 614 STD and a machinery protection system acc. API 670 STD.
SETCON was considered as the best solution for this application, due to its high efficiency performance, low voltage electronics and optimized installation space for potential follow-up retrofit projects. By choosing SETCON solution, PDO Petroleum Development Oman L.L.C. demonstrates their commitment to sustainability and reducing their carbon footprint.
Oman government has been taking steps towards energy efficiency and zero-carbon for years through several initiatives and policies aimed at reducing carbon emissions, as well as and increasing the use of renewable energy sources. Furthermore, the Omani government has implemented a number of energy efficiency measures, such as introducing regulations for energy-efficient buildings and appliances, promoting public transportation, and encouraging energy conservation practices in industries.
This project aligns with Oman’s efforts towards energy efficiency and sustainability, including their goal of reaching net-zero emissions by 2050, in line with the Paris Agreement objective of limiting global warming to 1.5°C. We are proud to be a part of this important initiative and look forward to continuing to contribute to a sustainable future for Oman.
About Petroleum Development Oman (PDO)
Petroleum Development Oman (PDO) is the leading exploration and production company in the Sultanate of Oman. We deliver the majority of the country’s crude oil production and natural gas supply, but above all we focus on delivering excellence, growth and sustainable value creation within and well beyond our industry. The company is owned by the Government of Oman (which has a 60% interest), the Shell Group (which has a 34% interest), Total (which has a 4% interest) and Partex (which has a 2% interest). Gas fields and processing plants are operated by PDO exclusively on behalf of the Government
About SULZER
Sulzer is a global leader in fluid engineering and chemical processing applications. They specialize in energy-efficient pumping, agitation, mixing, separation, purification, crystallization and polymerization technologies for fluids of all types. Their solutions enable carbon emission reductions, development of polymers from biological sources, recycling of plastic waste and textiles, and efficient power storage. Sulzer’s customers benefit from their commitment to innovation, performance and quality through their responsive network of 180 excellent manufacturing facilities and service centres across the globe. Sulzer is headquartered in Winterthur, Switzerland, since 1834.
SET hereby announces the completion of its SETCON automation test bench. This newly equipped test bench will allow SET to pre-test the entire functionality and software of the SETCON system, including communication to and from the DCS. It will also enable our customers to realistically accept the entire software by modeling the transmission. In addition, this test facility is also used for internal and external training purposes at SET and is intended to further improve the SETCON system in its functionality and availability.
Finally, the use of the automation test bench guarantees the functionality of the SETCON system and the smooth integration process at the customer’s site. Subsequent changes and adaptations at the customer’s site are thus to be avoided. Ultimately, this pre-testing approach saves time, costs and effort for all parties involved.
SET (Sustainable Energy Technologies) GmbH is delighted to announce the receipt of an order from the international energy company RWE Generation SE. The project will be implemented at the HKM thermal power plant Duisburg-Huckingen, Germany. It involves the replacement of an existing Voith R17 KGS hydro-dynamic geared coupling with the highly efficient SETCON® – electro-mechanical variable speed gearbox.
With a rated power of 5 750 kW and a rated output speed of 6 282 rpm, SETCON® is perfectly suited to meet on-site conditions, due to the matching gearbox footprint, which reduces implementation time and effort substantially. Furthermore, it will deliver significant energy savings compared to the status quo, with an average energy saving of more than 1 000 kW continuously.
In addition to the immediate benefits of increased efficiency, this project has the potential to lead to a follow-up order from RWE after the successful operation of this first SETCON® unit. This represents a major step forward in the efforts of SET GmbH together with RWE to reduce energy consumption and to promote sustainable practices in the power generation industry.
Energy efficiency is critical as it minimizes the amount of energy required, leading to lower energy costs, reduced greenhouse gas emissions, and improved energy security. Most recent investigations also confirm that energy efficiency is one of the most powerful methods for reducing energy-related emissions. Therefore, governments and organizations globally are enhancing energy efficiency through various policies and initiatives to set maximum energy efficiency levels for products and buildings. These initiatives have further promoted the utilization of energy-efficient technologies and practices, reducing energy consumption, emissions, and costs. SET GmbH is proud to be contributing to the shift towards energy efficiency and is confident that SETCON® technology will play an important role in meeting the growing demand for sustainable and environmentally relevant solutions.
About RWE RWE is leading the way to a green energy world. With an extensive investment and growth strategy, the company will expand its powerful, green generation capacity to 50 gigawatts internationally by 2030. RWE is investing more than €50 billion gross for this purpose in this decade. The portfolio is based on offshore and onshore wind, solar, hydrogen, batteries, biomass, and gas. RWE Supply & Trading provides tailored energy solutions for large customers. RWE has locations in the attractive markets of Europe, North America, and the Asia-Pacific region. The company is responsibly phasing out nuclear energy and coal. Government-mandated phaseout roadmaps have been defined for both energy sources. RWE employs around 19,000 people worldwide and has a clear target: to get to net zero by 2040. On its way there, the company has set itself ambitious targets for all activities that cause greenhouse gas emissions. The Science Based Targets initiative has confirmed that these emission reduction targets are in line with the Paris Agreement. Very much in the spirit of the company’s purpose: Our energy for a sustainable life. https://www.rwe.com/
About HKM GmbH Hüttenwerke Krupp Mannesmann GmbH has a core workforce of 3,000 employees and 191 trainees. The company produces 4.2 million tons of steel a year, which is processed into a wide range of everyday products, such as car bodies, washing machines and wind turbines. https://www.hkm.de/
About SETCON® SETCON® is SET’s proprietary electro-mechanical variable-speed gearbox designated to control the speed of large pumps and compressors. Compared to other variable-speed concepts, SETCON shows the highest overall efficiency and it is pioneering in terms of reliability and flexibility. Additionally, thanks to its matching footprint, SETCON is the ideal solution to replace low-efficient hydro-dynamic geared couplings.
