PowerLink PES PV-Storage Hybrid Energy System

—— A Case Study of Green Innovation in Tower Crane Drives

In today’s rapidly developing construction industry, tower cranes, as the “pillars of strength” on construction sites, rely on a stable power supply that directly determines construction efficiency, cost control, and compliance. Traditional tower crane power supply depends on diesel generators or high-voltage power grids, generally facing pain points such as fuel waste due to overcapacity, high peak electricity costs, excessive noise emissions, and difficulties in grid connection for remote construction sites. Especially against the backdrop of the in-depth promotion of the “dual-carbon” strategy and the accelerated implementation of green and intelligent construction, traditional power supply models are no longer suitable for the industry’s high-quality development needs. The PowerLink PES PV-storage hybrid energy system, with its full range of products precisely matched to tower crane drive scenarios, leverages the synergistic advantages of “PVs + energy storage” to provide the construction industry with an efficient, energy-saving, and compliant integrated power supply solution. The following details its core value and application results using real project case studies.

Case: High-efficiency power supply solution for a high-rise building project in a city center in the Middle East – a cluster of ultra-large tower cranes

Project Introduction

Located in the heart of a city center, this project involves the construction of a super high-rise commercial complex. Four tower cranes are deployed on-site, each with a peak instantaneous power of 67.5kW, totaling 270kW. They require 24/7 operation to ensure the project schedule is met. Initially, the project employed a traditional power supply model, utilizing multiple 800kVA ultra-large diesel generators. This not only resulted in enormous fuel consumption and high maintenance costs, but also conflicted with the stringent environmental regulations (LEZs Low Emission Zone requirements) of downtown Dubai due to the noise and emissions generated by the generators, frequently leading to fines. Furthermore, the generators’ prolonged low-load operation resulted in underutilization of the power source, causing severe wear and tear, frequent shutdowns, and significantly slowing down the construction progress.

Figure 1 PES400S Energy Storage Battery Project Application Diagram

Solution: PowerLink PES200S PV-Storage Hybrid Energy System Network Application

Based on the project’s total tower crane power requirements and on-site conditions, PowerLink customized two PES400S (200KW) PV-storage hybrid energy systems to form a smart microgrid, replacing traditional large diesel generators. A small 250kVA generator was added for auxiliary charging, forming a power supply mode of “energy storage as the main source and generator as the auxiliary source”. This perfectly matches the tower crane’s “roller coaster” power demand characteristics – the instantaneous peak power is supplied by the energy storage system in a fast response, and the regenerative power during the no-load and descent phases is recovered and stored by the energy storage system, realizing efficient energy recycling.

Simultaneously, the system integrates a PV inverter module, which can be paired with rooftop crystalline silicon PV panels (referencing the PV configuration logic of a 5MW total installed capacity project) to convert solar energy into electrical energy stored in an energy storage unit, further reducing dependence on fossil fuels and meeting the project’s green construction requirements. In this solution, the PES400S, with its peak efficiency of 98.5% and a wide operating temperature range of -20℃ to 60℃, perfectly adapts to Dubai’s high-temperature climate. Its intelligent air-cooling design and IP54 protection rating can withstand the harsh environment of the construction site, ensuring stable system operation.

Figure 2 Application schematic diagram of PES series

Application effectiveness

• Significant Cost Reduction and Efficiency Improvement: Fuel costs are reduced by 94%, generator operating time is reduced from 24/7 to 6 hours per day, and the required generator capacity is reduced from 800kVA to 250kVA. This reduced capacity significantly decreases equipment wear and tear, extends generator lifespan by 30-40%, and provides a return on investment in just 8-10 months, far exceeding the industry average.
• Compliance Guaranteed: The system operates with zero on-site emissions and zero noise (noise level <75dB), perfectly meeting Dubai’s low-emission zone and urban noise restrictions, completely eliminating environmental penalties, ensuring 24/7 compliant construction, and securing a competitive edge in project timelines.
• Stability and Reliability: The system features seamless switching between grid-connected and off-grid operation. The intelligent energy management system (EMS) monitors the operating status in real time with a fast response time, effectively absorbing regenerated power from the tower crane, smoothing power peaks, and avoiding downtime caused by power surges. The system maintains a 99% online rate, ensuring continuous and stable tower crane operation.

The entire PowerLink PES series is compatible with tower crane drive needs across all scenarios.

To address the power supply needs of tower cranes with varying power ratings in the construction industry (from small tower cranes to large clusters of tower cranes), we have developed a product matrix suitable for all scenarios. This matrix covers all models, including PES30S (30KW), PES60S (60KW), PES100S (100KW), PES200S (200KW), PES300S (300KW), PES400S (400KW), and PES500S (500KW), enabling single-unit compatibility and multi-unit networking to flexibly adapt to different construction scenarios.

• Small tower crane (30-60KW): Compatible with PES30S and PES60S, compact in size and flexible in deployment, suitable for small urban construction sites and space-constrained scenarios, can replace small diesel generators and achieve green power supply.
• Medium-sized Tower Cranes (100-200KW): Compatible with PES100S and PES200S models, offering high efficiency and stability, suitable for medium-sized construction projects. They can drive a single tower crane independently or be networked to support collaborative operation of multiple cranes.
• Large Tower Cranes/Tower Crane Clusters (300-500KW): Compatible with PES300S, PES400S, and PES500S models, providing powerful performance to handle the instantaneous peak demands of large tower cranes. Supports networked multi-system operation, suitable for large-scale construction projects such as high-rise buildings and large complexes, perfectly replacing traditional large diesel generators connected to the high-voltage power grid.
• All products utilize advanced energy management systems, supporting PV access, renewable energy recovery, and remote monitoring. They offer advantages such as wide operating temperature range, high protection level, and high energy efficiency, effectively addressing the core pain points of tower crane power supply in the construction industry and helping projects achieve multiple goals including cost reduction, efficiency improvement, compliance, and green operation.

Figure 3 PES400 Product Diagram

PES Series Parameter Table

Case Summary: Empowering the Green Transformation of the Building Industry with PV and Energy Storage Innovation

From the massive clusters of tower cranes in downtown Dubai to meticulous construction projects in Hong Kong’s core areas, the PowerLink PES PV-storage hybrid energy system has demonstrated its core competitiveness in the tower crane drive field through practical application results. Compared to traditional power supply modes, the PES system not only significantly reduces fuel consumption and operation and maintenance costs, shortening the investment payback period, but also perfectly meets stringent global environmental regulations and China’s “dual-carbon” strategy requirements, helping construction companies enhance their bidding advantages and establish a green corporate image.

The green transformation of the construction industry begins with innovation in every stage of construction. The PowerLink PES PV-storage hybrid energy system, with its full range of models, full-scenario adaptability, and full-process service, provides tower crane drives with a smarter, more efficient, and greener power supply solution, helping construction companies break free from the constraints of traditional power supply, achieve high-quality and sustainable development, and jointly build a new future of green and intelligent construction!