CASE STUDIES

Revolutionising Maintenance Efficiency & Safety with Instagrid

CLIENT

Fortescue

LOCATION

Port & Rail Division, Pilbara, WA

Fortescue is enhancing safety and efficiency across its Pilbara operations by replacing traditional generators with Instagrid’s portable, zero-emission battery systems as part of its drive toward decarbonisation and innovation.

Fortescue’s Port and Rail division based in the Pilbara region of Western Australia faced a complex operational challenge: performing maintenance on a reclaimer that continuously moves at 3km/h. Traditional methods relied on trailing cables or shutting down the machinery entirely to complete the necessary work.
Both approaches were inefficient and introduced safety risks or production delays. Across the wider Pilbara operations, mobile maintenance teams relied on 2-8 kVA generators. These units were noisy, space-consuming, required regular servicing and presented logistical burdens particularly in the Pilbara environment. Fortescue needed a safer, cleaner, and more efficient solution that could match the demands of their high-performance maintenance schedules.

Instagrid ONE Portable Battery System

APS supplied Fortescue with Instagrid’s ultra-portable battery system, weighing just 20kg’s, it provides the team with greater flexibility and safety during maintenance tasks.
By implementing Instagrid, Fortescue can now carry out essential work more efficiently and without the need to shut down critical infrastructure.
For the reclaimer, the new power solution means technicians can carry power with them and complete electrical work while the machine remains in motion, without the risks associated.
APS also worked with Fortescue’s rail maintenance division to replace traditional 2-8 kVA petrol generators with compact Instagrid units permanently installed in service vehicles.
This transition eliminates the need for fuel handling, noise management and ongoing servicing while also improving overall fleet efficiency.

Reduced Logistical Complexities with Seamless Integration

With Instagrid units in place, maintenance on the reclaimer can be conducted safely and efficiently without disrupting operations. The ultra-portable power source eliminates trip hazards and downtime.
Across the rail maintenance fleet, the move to battery-powered systems saved valuable space in vehicles, reduced logistical complexity, and enabled quieter emission-free servicing in remote locations.
The result was a seamless enhancement in day-to-day operations that improved safety standards, increased team productivity, and removed the dependency on fuel-based equipment.
Fortescue’s integration of Instagrid technology, facilitated by APS, has ensured maintenance workflows are more efficient and less disruptive, and the removal of extension leads and generator noise has created a safer and more streamlines work environment.
The project supports Fortescue’s broader decarbonisation strategy, offering a clean and quieter alternative to diesel-powered systems.

Following the success of the first Instagrid units over the past 12 months, Fortescue is now actively rolling them our across additional sites throughout the Pilbara. This project is a clear example of how battery energy storage systems can go beyond simply supplying power, they can transform site operations, deliver measurable cost savings and contribute to a decarbonised future. Following the success of the first Instagrid units over the past 12 months, Fortescue is now actively rolling them out across additional sites throughout the Pilbara. Instagrid units have become part of the standard fit-out across their maintenance fleet, and this continued adoption reflects Fortescue’s position as a global benchmark for responsible and innovative mining practices. This project is a clear example of how battery energy storage systems can go beyond simply supplying power. They can transform site operations, deliver measurable cost savings, and contribute to a more sustainable future.

FROM THE CLIENT

"Instagrid ONE units have become essential during our shutdowns and critical maintenance at our Pilbara operations. Their portability and zero-emission output allow us to maintain uptime without relying on diesel generators, aligning perfectly with our decarbonisation strategy."

– Fortescue

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