Variable-speed Gearbox for Pumps & Compressors

SETCON®

SETCON is an electro-mechanical variable-speed gearbox designed to control the speed of large pumps, compressors, fans and blowers. With the highest overall efficiency, compared to other geared VSDs, SETCON is an outstanding and reliable variable-speed drive for your application.
Rated Power: 2 MW – 15 MW
Input shaft: 1 500 rpm / 1 800 rpm
Output shaft: up to 15 000 rpm
Variable speed range: 20 % – 105 %
Area classification: Non-Ex, Ex
Energy efficiency: up to 97 %
• Integrated LOS (incl. lubrication of external units)
• Service-friendly and reliable design due to low-voltage electronics
• The existing Main Motor can be reused for retrofits (reduced CAPEX)
• Soft-start device” – Integrated soft start of Main Motor
• Footprint optimized for easy replacement of geared variable speed couplings
SETCON® The All-in-one Solution

= lowest life cycle costs (LCCs) on market

Why SETCON®

As oil and gas prices continue to fluctuate, the demand for CO2 reduced energy production increases and EU eco-design regulations are now becoming stricter and operators are turning towards controlled speed drives for their machines. What has become standard in other applications, namely adjusting the power required to actual needs, is not yet common practice in many areas of the industry. In case speed control is implemented, MV frequency converters or hydro-dynamic gear couplings are usually installed. However, when high electrical drive power is required, investment costs and efficiency losses are often high. SETCON on the other hand combines all the benefits of variable-speed drive technologies, thus delivering extremely high efficiency, minimal footprint, and maximum reliability for reasonable investment costs.

Set-up

Set-up Drive Train

1. Gearbox incl. lubrication unit
2. Servo(s) (ASM)
3. 4Q LV- Frequency Converter (e.g. 690 V)
4. Control Cabinet incl. PLC
5. Main Motor (e.g. 10 kV)
6. Driven Machine (e.g. Pump)

Functional description

The SETCON® System consists of a Gearbox incl. differential gear (planetary gear) (1), Servos in combination with a low-voltage Frequency Converter (2+3) and a Control Cabinet (4). The constant power supply is done by an electric motor as the medium-voltage Main Motor (5). The variable output is transmitted to a Driven Machine (6) e.g. a Pump or Compressor. The medium-voltage Main Motor (5) is connected directly to the MV-grid and drives the planetary gear’s ring gear at constant speed. The differential gear’s sun wheel transmits the variable speed through an optional high-speed gear unit (offset alignment) to the Driven Machine (6). The differential gear’s planet carrier is connected to the Servos. The speed of the Servos (2) is controlled firstly in order to ensure the speed at the Driven Machine (6) is variable when the speed of the Main Motor (5) is constant, and secondly to control the torque in the entire drive train.

Retrofit Project

SETCON® Flagship Project in Germany

SETCON variable speed gearbox has been successfully running at the power plant Mittelsbüren in Bremen, Germany operated by swb Erzeugung AG. As the retrofit project, SETCON gearbox provided energy savings of app. 12 800 MWh per year. SETCON SE6 replaced the existing...

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