Cutting Generator Runtime by 80% at a Remote Compound
Select Plant Hire
ORANA Transmission Project
Industry: Utilities and transmission infrastructure construction
By Jonathan Elsley, General Manager Business Development and Sales EA, Fuelfix | Published October 2026
Integrated Hybrid Power
Solution Delivered
Reliable 24/7 power for a remote office and accommodation compound, with less diesel use, generator runtime, maintenance and emissions.
What was delivered
- Hybrid power system comprised of Fuelfix ESU150 Battery Energy Storage System (BESS), PDU250 Power Distribution Unit a 150kVA diesel generator for backup
- Temporary site power infrastructure
- Remote site energy management
- Engineering, site commissioning and technical support
What are the operational benefits of the solution
*Annualised Estimated Benefits:
- 80% less generator runtime - cut down by 6,580 hours
- 81,000L diesel saved
- 219 tonnes fewer CO₂ emissions
- 19 bulk fuel deliveries avoided
- 13 less major generator services per year
- 24/7 power for 51 buildings
- About $178,200 in fuel saved, at $2.20/L
Reduced fuel consumption, lower maintenance requirements, fewer refuelling and servicing activities, improved site safety with less vehicle movement and personnel exposure to higher-risk activities.
Project Overview
Select Plant Hire needed reliable, round-the-clock power for a remote office and accommodation compound supporting the ORANA Transmission Project near Dunedoo, NSW. Fuelfix designed a hybrid power system where the battery carries the load and the generator runs only when it is needed.
The 51-building compound runs 24/7. Demand nearly tripled in three months as occupancy grew and winter heating built up, from 5,578 kWh in May to 15,658 kWh in July. The system absorbed the increase without reconfiguration.
This isn’t only a transmission-project problem. A remote camp with a constant base load, a long way from fuel and service crews, is the same challenge faced on mine site camps, construction and civil compounds, and shutdown facilities across Australia. The generator sits at low load, burns more fuel than it should and needs servicing more often.
Run conventionally, the compound would have had a generator running 24/7 at 20–30% load.
That range is inefficient for a diesel engine and prone to wet stacking, where unburnt fuel and carbon build up because the engine is running too lightly. The result is high fuel consumption, long generator hours, frequent servicing and higher emissions.
On this project, the key challenges were:
- Supporting variable demand across offices, accommodation, HVAC, kitchens, hot water and site infrastructure
- Integrating the ESU150, PDU250 and generator with the site’s electrical distribution network
- Coordinating electrical interfaces, communications cabling and installation with multiple stakeholders
- Managing mobilisation, transport, factory acceptance testing and commissioning within project timeframes
- Cutting diesel use and emissions without risking reliability
What were Tasman objectives
- Reliable three-phase power for 51 buildings, 24/7
- Less diesel use and fewer generator operating hours
- Fewer bulk fuel deliveries and major generator services
- A system that could cope with changing loads as occupancy grew
- Lower site CO₂ emissions
Why they choose Fuelfix Integrated Solutions
Select Plant Hire wanted a supplier who could size, integrate and commission the whole system, not just supply a battery.
Fuelfix brought experience with hybrid power on remote sites, along with in-house engineering and commissioning support.
Solution
After assessing the site’s load profile, Fuelfix delivered a mobile hybrid system that works as one coordinated unit:
ESU150 Battery Energy Storage System (BESS)
Three-phase mobile battery, up to 150 kW with 225 kWh of storage. It is the primary power source and carries most of the load.PDU250 Power Distribution Unit
A 250 kW unit that controls the battery and generator, managing charging and distribution.150kVA diesel generator
Recharges the battery, provides redundancy and supports peak loads. It starts automatically only when needed and runs in its efficient load range.Because the battery and generator work together, the compound keeps power if either needs maintenance. When charging is required, the generator automatically starts and operates in its optimal efficiency range of around 75% load rather than running continuously at low load. Even as winter demand increased and site energy consumption nearly tripled, the system maintained reliable supply while significantly reducing generator dependency.
Select Plant Hire and Fuelfix worked together to develop a practical solution that addressed the site’s specific operational requirements while delivering improvements in efficiency, safety and sustainability.
The key challenges of the project were managed through a staged rollout, finishing with commissioning at the end of April 2026.
In its first three months (1 May to 31 July 2026), the generator ran for 443 hours instead of 2,208, while site demand nearly tripled.
- Cut generator runtime by 80%, leading to less wear on the diesel unit
- Saved 20,370 litres of diesel, worth approx. $44,800 at $2.20/L
- 5 less bulk fuel deliveries, cutting logistics costs and disruption related to each 4,250 L refuelling transfers
- 3 major generator services deferred, because the system avoided 1,765 generator hours against a 500-hour service interval. That means lower costs associated to technician mobilisations and maintenance services
- Delivered 29,860 kWh across 109 battery cycles, providing reliable power to 51 buildings, 24/7
- Fewer trucks on site. Less bulk fuel deliveries mean fewer heavy vehicles arriving at a remote site, and less refuelling transfers
- Less fuel handling, and less exposure to refuelling and spill risk
- Fewer technician visits for generator servicing
- Reduced CO₂ emissions by 54.7 tonnes
How we measured this?
- Period: 1 May to 31 July 2026 (92 days)
- Baseline: A conventional generator-only system would have run 24/7, typically at 20–30% load. That gives 2,208 hours (92 days × 24), the operating model the compound would otherwise have used.
- Diesel and emissions: Actual site data combined with industry-standard assumptions for generator fuel consumption and efficiency. Emissions factor ≈ 2.68 kg CO₂-e per litre of diesel (scope 1, Australian National Greenhouse Accounts)
- Fuel cost: $2.20/L
- Major service: Every 500 generator operating hours
- Bulk fuel delivery: 4,250 L per full tank replenishment
*Annualised figures are indicative and assume a load profile broadly consistent with the reporting period. Where site demand continues to grow, absolute savings would be expected to increase in line with it.
Based on measured performance over the first three months, the system is projected to deliver these annual benefits compared with a conventional generator-only installation:
Data sources, baseline and assumptions
The savings figures in this case study are based on actual site operating data combined with industry-standard assumptions about generator fuel consumption and efficiency. While actual results may vary, this method gives a reasonable representation of the fuel, emissions and operational savings attributable to the hybrid power system.
The annualised projections use actual data collected between May and July. Two of those three months fall in winter, when site demand is typically higher, so the load profile may not represent annual average consumption. As demand drops in warmer months, the BESS is expected to supply an even greater share of the site's energy, potentially delivering fuel, maintenance and emissions savings above those projected here. The annualised results should therefore be viewed as a reasonable and potentially conservative estimate of long-term performance.
Customer Testimonial
Throughout the project, the Fuelfix team worked closely with Select Plant Hire and the multiple stakeholders on site to ensure objectives were met and timelines maintained.
The Fuelfix hybrid power system delivered great operational and environmental outcomes while maintaining reliable power supply with significant reductions in maintenance and site movements.
“The ORANA project required a reliable and efficient power solution capable of supporting our remote accommodation and office facilities while reducing operating costs and environmental impact. Fuelfix worked closely with our team to deliver a practical hybrid power solution that combined battery storage, intelligent power management and generator integration. Their technical expertise, responsiveness and support throughout commissioning helped ensure a smooth deployment and delivered meaningful fuel savings from day one."
Name - Role at Select Plant Hire
Trusted to Deliver Integrated Power Solutions
This project shows how Fuelfix combines battery storage, power distribution and generator optimisation to cut diesel use and keep remote sites powered. In line with our Two Pathways, One Goal Strategy, we work with customers to develop practical energy solutions that reduce operating costs and emissions without compromising reliability. For Select Plant Hire, that meant 80% less generator runtime, fewer fuel deliveries and reliable power for 51 buildings, 24/7.
See the same approach at a Pilbara mine site in our Tasman Power case study, or discover how hybrid power systems compare to traditional diesel generators.
Ready to cut diesel use on your next site?
Planning a remote camp, compound or site facility? Talk to our team about a hybrid power solution sized to your load profile.
Hybrid power solutions
Battery Energy Storage Systems (BESS)
Temporary site power for hire
Engineering, commissioning and technical support
How much diesel can a battery and generator hybrid save at a remote camp?
At the ORANA compound, the hybrid system saved 20,370 L of diesel in three months and cut generator runtime by 80% against a generator-only baseline.
Why is running a generator at low load a problem?
At 20–30% load, a diesel generator burns fuel inefficiently and is prone to wet stacking, which increases maintenance. A battery lets the generator run only when it can work in its efficient range.
Does this apply to mine sites and construction compounds?
Yes. Any remote site with a constant base load and long fuel and service runs faces the same issue. Our Tasman Power project delivered an 82% generator runtime reduction at a Pilbara mine site.
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