SETCON 6 MW is getting ready for German project

SETCON variable speed gearbox with the power of 6 MW is getting ready for lubrication tests in frames of a German project. It will replace a geared fluid coupling and increase the energy efficiency by app. 1 MW.

SETCON minimizes power losses due to its electro-mechanical design and the ability to regenerate energy in partial load operation. The SETCON installation is proved to be short-term because of the footprint optimization to the exact sizing.

See other SET #retrofit_references: Retrofit-Project-swb_SETCON-SE6.pdf
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Find out more about SETCON: https://set-solutions.net/setcon/

SETCON variable speed gearbox with the power of 6 MW is getting ready for lubrication tests in frames of a German project. SETCON will replace a geared fluid coupling and increase the energy efficiency by app. 1 MW.

High energy efficiency is obligatory for industries to stay competitive

– said the Executive Director of the International Energy Agency (IEA) Fatih Birol in the frame of World Economic Forum 2024 this week:

Investments in energy efficiency are the most important now. In most cases, they pay back in 2-3 years… Even regardless of climate, just for our pockets, for our energy security, and also remain competitive. The companies who do NOT put enough emphasis on energy efficiency will be less competitive vis-a-vis others. This is a real fact now”.

With SET Sustainable Energy Technologies GmbH, the energy efficiency goal is more realistic than ever nowadays. Read our article about SETCON variable-speed drive to find energy benefits for your industry: “Why SETCON is the most energy efficient VSD on market”

Why SETCON is one of the most energy efficient VSD on market – Sustainable Energy Technologies GmbH

SETCON let your Main Drive start smoothly

SETCON let your Main Drive start smoothly

SETCON Servos help the Main drive to operate more efficiently, avoid overloads, costly equipment damage, and downtimes. Surely, it is all about SETCON Soft-Start mode. This integrated technology allows to start up the whole drive train very smoothly, with a minimum time of inrush currents.

The frequency controlled SETCON Servos gradually ramp up the whole pump string from 0% speed and acting as so-called pony motors. While starting, the Main drive is disconnected from the high-voltage (HV) grid, until the Main drive reaches synchronous speed, at a pump speed of app. 50%. Herby, the Main drive´s rotor is rotating in unison with the entire drive train to build up the necessary magnetic flux. Now by connecting the accelerated Main drive to the HV grid, the time for inrush currents is reduced significantly, in comparison to DOL (direct online) starts.

The SETCON Soft-Start mode is one of the most efficient solutions for reducing inrush current as the device enhances the voltage gradually and without stress for the system. Therefore, SETCON is cost-effective in comparison with, i.e., a Main drive overload protection system, which may cause additional losses of overall drive train efficiency.

An inrush current is a time limited, very high current which a Main drive faces once started from zero speed. It can have a multiple factor (up to 6 times) of rated current during starting procedure over a certain time period. Regular experiencing of high inrush current can cause motor damages, voltage dips in the supply line (which can consequently affect other equipment) and interrupt the proper Main drive start. Furthermore, the higher level HV grid has to be designed and protected for these cases.

Inrush current without SETCON
Inrush current without SETCON

The Inrush current is physically inevitable, but you can choose one of the most minimizing solutions with SETCON: www.set-solutions.net/setcon

SET ran a successful testing of the newest version of SETCON software

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.

Keep updated – follow Sustainable Energy Technologies news also on LinkedIn

SET ran a successful testing of the newest version of SETCON software

Interesting facts about SET Planetary gear stage

Interesting facts about SET Planetary gear stage - Sustainable Energy Technologies

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.
Sustainable Energy Technologies Planetary gear stage 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.

SET upgraded its manufacturing capabilities

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.

Keep updated – follow Sustainable Energy Technologies news also on LinkedIn

Sustainable Energy Technologies areas of gearbox assembly and testing cooperate with much higher flexibilit