Saudi Parter
Tower cranes require huge generators for startup surges but use little power during operation, causing waste. By switching to a VANGE Hybrid System, a Dubai site reduced generator runtime by 60% and fuel costs by 30%.While this project was in Dubai, the same challenges applies to high-temperature sites in Riyadh, NEOM, and Jeddah.
If you manage a construction site, you know the sound of money burning. It’s the sound of a massive 500kVA diesel generator rumbling away all day, spewing black smoke, just to power a tower crane that—let’s be honest—is sitting idle half the time.
This is what we call the “Tower Crane Paradox.”
"Tower cranes have massive starting currents (inductive loads), forcing you to rent an oversized generator. But once running, the load drops, leading to generator wet stacking and fuel waste."
We recently implemented a solution for a construction project in Dubai that solves this exact problem. The site had three large Tower Cranes (Potain & XCMG) and a double-cabin Hoist.
| Parameter | Old Way (Diesel Only) | New Way (PORTA Hybrid) |
|---|---|---|
| Generator Size | Multiple Generators (Oversized) | Single 100kVA Generator |
| Runtime | 24 Hours / Day | 3-4 Hours / Day |
| Fuel Efficiency | Low (Wet Stacking risk) | Max (Running at 80% load) |
| Maintenance | Frequent | Reduced by 60% |
The diesel generator runs at its optimal efficiency point (approx. 400kW output) to charge the battery. It only takes 3-4 hours to fully charge the system.
Once the battery is full, the generator turns OFF. The BESS takes over, supplying pure, silent power to all three cranes.
A single full charge can support the site's power consumption for 1.5 days.
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By switching from “Always-On Diesel” to “Hybrid Storage,” the project achieved massive reductions:
For the site’s double-cabin hoist, we used a smaller, dedicated package: a 100kVA Generator paired with a 100kW / 200kWh BESS. The generator runs for just 3 hours to charge the battery, and the battery handles the hoist for the rest of the day.
Not sure if your crane is wasting fuel? [Use our Free Project Planner] to calculate the exact generator size you actually need.
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