In one of Australia’s most resource-rich regions, the Port Hedland Solar and Battery Project demonstrates how renewable energy can support critical industries even in the face of extreme weather conditions.
In the Pilbara, where strong winds and heavy rains regularly pummel the coastline, resilient energy systems are essential for keeping critical industries on their feet.
Port Hedland, Australia’s largest iron ore port, depends on consistent power to support its massive resource operations, but its location on the cyclone-prone coast of the Pilbara adds a layer of complexity to any energy project – particularly those involving renewables.
However, through the Port Hedland Solar and Battery Project, APA Group is redefining what’s possible for renewable energy in extreme climates.
By integrating a robust solar and battery system with cyclone-resistant design features, the initiative demonstrates how clean energy can thrive in even the harshest conditions.
Cleaner energy for the Pilbara
Port Hedland is a vital economic hub, whose operations contributed a staggering $103 billion to Australia’s GDP during FY23.
“It’s like nothing you’ve seen before. It’s a massive engine room of the Australian economy and has been for the past decade,” Dale Cartwright, Head of Construction on the Port Hedland Solar and Battery Project, said.
The region has traditionally relied on non-renewable resources to power its operations, he said. This is partly because coastal solar farms have lagged behind inland installations due to the difficulty of designing structures that can endure extreme wind speeds.
However, as APA’s customer BHP has committed to greenhouse gas Scope 1 and Scope 2 reductions of 30 per cent by 2030, green energy is no longer a nice-to-have.
“APA is committed to partnering with customers to achieve their decarbonisation goals and has some of the largest renewable and storage assets in the the region, including the utility-scale solar farm (Chichester solar farm 60 MW) and battery (Newman BESS 35 MW/11 MWh) in the Pilbara,” Cartwright said.
WIth the launch of the Port Hedland Solar and Battery Project in 2022, APA set out to bring more renewable energy into the equation by combining a 45-MW solar photovoltaic facility with a 35 MW/36.7 MWh battery energy storage system. This hybrid system connects to APA’s Port Hedland Power Station, a critical energy source for mining giant and customer BHP.
By replacing thermal power with solar, the project is reducing emissions from the electricity powering BHP’s Western Australia Iron Ore port facilities. At the same time, the BESS ensures the energy security needed to support one of the country’s most important industries.
Building for extreme weather
During the planning stages for the Port Hedland Solar and Battery Project, the most glaring challenge facing APA engineers was the coastal region’s cyclonic conditions.
“The project is in Region D according to the Australian Standard, which is the highest cyclone risk category under the National Construction Code,” Cartwright said.
Despite this, Cartwright’s team took on the challenge of building a solar farm that could endure even the most severe cyclones.
“Our insurers asked us to design for a one-in-500-year event…. So it’s built to a wind speed of 80 metres per second, or 288 km/h. That speed has never been recorded on the Australian mainland – it’s only been observed offshore.”
To achieve this, over 32,000 steel piles are used to support 11,700 t of structural steel and almost a quarter of a million bolts, with fixed-tilt solar panels set at a 10-degree angle to minimise the impact of strong winds.
Typically, solar farms use tracking systems that allow panels to rotate, Cartwright said. In high winds, these systems are designed to flatten or “stow” the panels, which can cause catastrophic failure due to torsional galloping under extreme conditions. Fixed-tilt designs eliminate this risk.
“We also tested the panels extensively. We sent them to the Cyclone Testing Station at JCU in Townsville … There, we conducted cyclic tests to simulate extreme cyclonic conditions. We flexed the panels 10,000 times to try and break them, but the solar panels and associated bolted connections did not fail.”
APA’s future at the forefront of renewable energy
The Port Hedland Solar and Battery Project is a part of APA Group’s broader commitment to advancing the renewable energy transition in Australia.
By demonstrating that renewable energy can be both resilient and cost-effective in challenging environments, Port Hedland is paving the way for future projects of a similar nature.
“Our Port Hedland project showcases how solar, battery and gas-powered generation can work together to successfully transition mining operations,” Cartwright said.
“APA’s projects are nation-building, critical infrastructure that support the backbone of the Australian economy. Particularly for young engineers, working with APA is an exciting opportunity to contribute to something meaningful.”
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