SET presents SETCON SE6

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
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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 11,500 MWh and 11,100 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 over 4 MW and rated speeds of over 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

 

SETCON Raffinerie

BEKOnews: BEKO’s digitization know-how under testing conditions

The latest edition of BEKOnews from the company BEKO (www.beko.at) reports on the excellent cooperation with SET GmbH. Together, a high-performance test bench was developed and realized for an international customer.

The digitization experts at BEKO’s Hardware and Software Development Competence Center are already a SET partner since 2017. The BEKO team developed the measuring software for the transmission test bench, where the mechanical components of train and subway gearboxes undergo comprehensive quality testing during their development phase. The test bench can measure and record vibrations, temperatures, speeds and torques up to 100,000 samples per second for up to 200 channels ……

Link to article (only German version is availiable): BEKOnews: BEKO’s digitization know-how under testing conditions

 

SET Engineering

In addition to our innovative products for speed control in industrial and wind power application, SET offers its customers tailor-made engineering service. From mechanical and electriacal engineering to simulation and automation, SET offers a comprehensive portfolio of service. For the individual e-motor test lab and gearbox testbench development, we combine our interdisciplinary application know-how.

For our current Engineering Folder please click >here<

SETCON for New Drives and Retrofits

For constructing new drive systems, SETCON represents the best solution for high energy savings and low investment costs. Due to the reduced package seize, lower oil volume/oil cooling, minor heat generation/air conditioning and pipework, the investments will be minimized.

Furthermore, the Main Drive can be downsized by up to 20% of total power rating, influencing total project costs positively.

For Retrofits SETCON can be implemented into existing drive systems without repositioning main components in most cases. By replacing e.g. a hydro-dynamic Coupling, the Main Drive as well as the Driven Machine remain in an original state. Both the mechanical and electrical interfaces are ideally matched to replace existing drives.

SETCON has the potential to boost both efficiency and performance and to ensure a sustainable and reliabel operation.

 

SET presents SETCON

Recently SET carried out an organisational repositioning process. Due to a new market segmentation, supply structure and product identity, SET is introducing a new product name for its industrial EMDS Technology:SETCON® is based on SET´s in-house core technology and will replace the product name Contron. Furthermore, SETCON® guarantees highest quality, durability and maximum reliability to its customers. A newly developed footprint optimisation makes SETCON® more flexible than ever and gives a competitive advantage for new project implementations. Especially for retrofit projects SETCON® integration and replacement of existing drive concepts have never been so simple and cost saving before.

SETCON® will be developed, manufactured and tested at SET GmbH in Austria, in the heart of Europe. This will assure a high added value due to unique technological leadership and extensive experience in drive-train technology.

For further information or inquiry of new sales material please contact us.

MaschinenMarkt: Innovative Dreh-Zahlregelung

The Austrian professional journal “MaschinenMarkt” has published the new drive technology CONTRON(Today SETCON®) by SET GmbH in its latest issue. Mr. Maximilian Hehenberger, the head of business development and sales at SET GmbH, presents this innovative solution in his article with the title ”Innovative Dreh-Zahlregelung”. To read the whole article, please klick [here]

SET GmbH has been nominated for the Carinthian Innovation and Research Prize 2016

Since 1991, the Kärntner Wirtschaftswährungsfonds (KWF) has been awarding the Carinthian Innovation and Research Prize. Each year a jury is distinguishing highly innovative Carinthian companies in three categories:

  • micro enterprises
  • small and medium-sized businesses
  • major enterprises

On 24th November 2016 SET GmbH has been nominated for this prize in the category “small and medium-sized businesses” with our outstanding project “Variable Speed Electro-Mechanical Gearbox”. It has to be mentioned that we were the only company of our sector which was nominated at the award ceremony in the Lakeside Park Klagenfurt. This nomination proves that SET GmbH can be seen as a reliable business partner in implementing highly innovative ideas.

More details on our project can be found [here]

innovationspreis-2016_set_gruppenfoto1

Projektteam SET: Innovations- und Forschungspreis 2016

Presentation at CWP 2016

For the first time SET GmbH is presenting its new innovative product the TRD-unit (Torque Ramp Down Unit) at the China Wind Power 2016 (20th of October, Beijing).

Content:china-windpower-2016 The TRD-unit is a wear-free Eddy Current brake (ECB) which reduces the loads of a WEC in case of a LVRT or any other unpredictable failure.  High stress cannot be prevented, so the WEC has to be designed for these cases. This can be seen by the large amount of material used for WECs (e.g. DFIG) already in operation, which led to an increase in overall costs. To minimize these dimensioning loads, the company SET GmbH from Klagenfurt in Austria has developed a robust, very controllable and cost effective system: a wear-free Eddy Current brake (ECB) mounted on the generator’s HSS under the brand name TRD-unit.  The TRD-unit is an effective option for slowing down a WEC within a short time period, before the WEC´s pitching system is able to react.

This leads to the fact, that the structural loads due to LVRT are no longer dimensional loads. Foundation, tower, rotor blades, gears and bearings can be designed under load reduced conditions. It is expected that the saving of materials lies in the lower two-digit percentage range.

CWP2016, Presentation of SET´s TRD-unit, Maximilian Hehenberger (November 20th, Beijing)

CWP2016, Presentation of SET´s TRD-unit, Maximilian Hehenberger (November 20th, Beijing)

SET presented at 13th European Fluid Machinery congress

At 13th European Fluid Machinery congress Mr. Maximilian Hehenberger, the head of Business Development & Sales of SET GmbH, has presented his article with the title “Increased Efficiency and Reliability through an Electro-Mechanical Differential System Providing Variable Speed to Pumps and Compressors”.

Content: The objective of this article is to assess an electro-mechanical differential system (EMDS) 13th European Fluid Machinery Congress_Logosystem providing variable speed to a driven machine (e.g. compressor, blower, pump, etc.) in terms of applicability and energy Efficiency.

At the beginning of 2015 the European Union released a new standard, the EN 50598 series, leading to increased demand for variable speed drives. Beyond other drive train technologies, the EMDS is one possible solution for meeting the standard’s requirements. In this connection, efficiency and the resulting life cycle costs are essential to ensure compliance. The assessment of the EMDS reveals that this drive train technology is a compatible solution to meet future challenges…to read the whole article klick [here].

13th European Fluid Machinery Congress

 

Compressor, Blower & Fan Technology: Assessment of an electro mechanical differential gear providing variable speed to industrial application

The professional journal “Compressor, Blower & Fan Technology”  (the only technical journal for compressor and fan technology  in China) has published the CONTRON(Taday SETCON®) technology by SET GmbH in its latest issue. Mr. Maximilian Hehenberger, the head of business development and sales of SET GmbH,  presents this innovative solution in his article with the title ”Assessment  of an electro mechanical differential gear providing variable speed to industrial application”. To read the article, please klick [here].

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