SOLAR FARM CONTROL SYSTEM and NetWork Design /
PROJECT OVERVIEW
Tier16 was engaged to design and implement a landmark 45MW solar farm control system (SFCS) integrated with an existing power station in the Pilbara.
As the first large-scale renewable facility in the region, the project represents a major step forward in decarbonising remote mining operations.
Designed to withstand extreme wind conditions of up to 300 kph, the solar facility is forecast to supply 100% of the miner’s average daytime energy demand.
CLIENT CHALLENGE
The client faced the challenge of integrating large-scale solar and battery assets into an existing gas-fired power station without compromising power reliability for critical mining operations.
Multiple sub-systems from different suppliers had limited interface definitions, and there was no opportunity for pre-installation testing.
As a first-of-its-kind renewable project in a remote environment, the system needed to perform reliably from day one despite significant technological uncertainty.
THE TIER 16 solution
Tier 16 acted as the recommended Lead Systems Integrator, designing and delivering the Solar Farm Control System (SFCS) to enable seamless integration between solar, battery, and gas generation assets.
The SFCS encompassed both primary and secondary systems, including all related equipment and infrastructure. A key feature was the integration of a SCADA system, providing real-time monitoring and centralised control of solar irradiance, power output, and equipment status – essential for efficient solar farm operations.
Tier 16 demonstrated exceptional problem-solving capability. Despite no pre-installation testing, the team quickly mastered new technologies and adapted designs on site to ensure stable, reliable system performance from day one.
The project scope included:
OT hardware procurement
Control system and network engineering
PLC, DCS software development
SCADA software development
Control system integration
Project delivery documentation
Factory acceptance testing (FAT)
Site acceptance testing (SAT)
Onsite commissioning
Develop operator training documentation
Provide operating training
TECHNOLOGIES USED
Rockwell ControlLogix PLC’s
Aveva GeoSCADA
Honeywell Experion PKS SCADA
PROJECT OUTCOMES & IMPACT
Tier16’s role shows how expert system integration and agile adaptation under technological uncertainty can transform complex projects into reliable, scalable energy solutions for remote mining operations.
Advanced SCADA Monitoring: Delivered real-time visibility and centralised control of solar, battery, and gas assets, enabling operators to optimise performance and maintain reliability.
Energy Enablement: Accelerated the miner’s transition to cleaner energy to meet daytime demand.
Agile On-Site Adaptation: Adapted to new technologies on site and overcame limited interface information, delivering a fully operational system despite no pre-installation testing.
Seamless multi-vendor integration: Integrated multiple subcontractor systems with limited interface definitions to enable smooth commissioning, reduce risk, and meet tight operational deadlines.
Robust Network Design and Implementation: Designed a robust field network connecting redundant converters to common communications cabinets.
CLIENT TESTIMONIAL /
Tier16, one of our EPCM subcontractors, developed the control system design with a strong focus on achieving robust performance through appropriate redundancy and fault tolerance. Their work effectively addressed critical requirements related to cyber security and long-term hardware sustainability, reducing the risk of future obsolescence. Tier16 demonstrated diligence & professionalism throughout the project, proactively troubleshooting network issues and responding to inverter functionality changes introduced at short notice by hardware vendors. Brandon B.