NSJ BESS – SCADA

Challenge / Problem: Fortescue’s North Star Junction Battery Energy Storage System (NSJ BESS) forms a critical part of its Pilbara decarbonisation strategy, requiring a highly reliable, grid-forming SCADA system capable of supporting a large-scale, complex asset. The project presented significant technical and delivery challenges, including the integration of approximately 125,000 tags across direct SCADA interfaces and redundant RTU architectures, alignment with Fortescue engineering and cybersecurity standards, and delivery within a fixed schedule while minimising site exposure in a remote location. Ensuring system performance, availability, and testability prior to site commissioning was essential to mitigate project and operational risk.

Solution:  Pivotal Engineering delivered a structured, low-risk SCADA integration solution based on Ignition 8.1, leveraging standards developed by Pivotal Engineering as part of a previous engagement. The solution included end-to-end SCADA design, configuration, RTU programming, database setup, and HMI development, supported by formal 30% and 60% design reviews. A dedicated test network and principal-supplied hardware were established in our lab to enable comprehensive Factory Acceptance Testing, including client-witnessed FAT. Robust project controls, detailed functional specifications, alarm and I/O schedules, and fully documented FAT and SAT procedures ensured transparency, quality, and alignment with Fortescue’s delivery expectations.

Outcome / Results:  The NSJ BESS SCADA system was delivered with a high level of quality, reliability, and readiness for site commissioning, enabling efficient Site Acceptance Testing and rapid transition to operations. The off-site development and testing approach significantly reduced commissioning risk, site time, and rework, while ensuring consistent system performance across all BESS components. The final solution provided Fortescue with a scalable, maintainable, and future-ready SCADA platform that supports real-time monitoring, control, reporting, and training—directly contributing to the successful deployment of critical infrastructure supporting Fortescue’s real zero emissions by 2030 objective.