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Power Generation

Ironbark Power Station


Client
Fitzroy Australia Resources
Duration
Oct 2023 - Jun 2024
Location
Moranbah, Queensland, Australia
Value
$1.9 million
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A high-performance embedded generation project supporting Fitzroy’s shift toward cleaner, self-sufficient power.

Ironbark Power Station forms a critical part of Fitzroy Australia Resources’ energy strategy to convert waste coal mine gas into reliable onsite power. Located in Queensland’s Bowen Basin, the station services the Ironbark No. 1 Coal Mine and reflects the sector’s shift toward low-emission generation and operational self-sufficiency.

The facility is designed to expand from 5MW to 20MW, with PHE Group engaged to deliver the full electrical and instrumentation (E&I) package for the initial 5MW stage. The works spanned hazardous area installations, HV infrastructure, and detailed commissioning support across Stages 1 to 3 – all executed within a highly regulated mine site environment.

Project Scope

  • Delivered full E&I works to support Fitzroy’s Stage 1 rollout of its embedded generation strategy.
  • Completed hazardous area installations and compliance inspections in accordance with AS/NZS 60079 standards.
  • Delivered and commissioned three 11kV/415V transformer kiosks, including all associated cable support systems and terminations.
  • Performed detailed HV pre-commissioning activities, including testing of 11kV systems, HV switchboard protection settings, SCADA integration, and metering verification.
  • Installed and terminated 11kV HV cabling and underground conduit systems across site infrastructure, including a site wide HV earth grid to support system safety and redundancy.
  • Installed LV and control cabling, switchboards, distribution boards, and electrical systems for amenities and switchrooms.
  • Supported Stages 1–3 commissioning, including fall-of-potential testing, generator protection, Modbus mapping, and SCADA-ready metering integration.

Innovations and Solutions

  • Delivered all works within a highly regulated live mine site, aligning with Queensland Coal Board protocols and Fitzroy’s site-specific requirements.
  • Adapted to the mine’s 10/4 roster (including travel), restructuring delivery to maintain momentum despite reduced site access.
  • Navigated evolving design inputs through real-time coordination with Fitzroy and delivery partners to avoid rework and keep commissioning on track.
  • Maintained delivery momentum despite regional supply constraints by engaging local suppliers and re-sequencing site activities to suit material availability.

Outcomes and Benefits

  • Reinforced PHE’s capability in high-risk, embedded generation projects – positioning the team for future delivery as Fitzroy’s generation strategy scales.
  • Supported Fitzroy’s broader decarbonisation goals by displacing grid dependency and improving site energy self-sufficiency.
  • Completed works in a live mining environment with zero safety incidents.
  • Positioned the power station for seamless expansion to its full 20MW capacity.
Project Images
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