Remote industrial operations face a persistent challenge that conventional power solutions cannot address: infrastructure that cannot keep pace with project timelines. When an exploration contractor must energise a new drill site within three weeks, or when a construction project must relocate every six months, traditional power approaches become expensive obstacles rather than enabling infrastructure. Diesel generators burn through fuel budgets whilst accumulating ongoing logistics costs. Fixed solar installations make no economic sense for temporary locations. Stand-alone systems require extensive site preparation work, adding weeks to deployment timelines.
Hybrid solar skid systems solve this fundamental mobility problem by packaging complete renewable power plants onto transportable frames. These self-contained units combine solar photovoltaic panels, battery energy storage, diesel generators, and intelligent control systems into standardised modules that can be trucked to site, connected, and commissioned within days rather than months. For operations across Western Australia’s Pilbara, Kimberley, and Goldfields regions, and increasingly across Australia’s remote industrial landscape, transportable power systems transform how projects approach power supply during exploration phases, construction periods, and staged expansions.
What Makes Skid-Mounted Systems Different
Unlike conventional power installations that require concrete pads, structural mounting engineering, and extensive electrical cabling work, hybrid solar skid configurations arrive as complete plug-and-play units. The structural steel frame, specifically designed for crane lifting and truck transport, serves simultaneously as both the installation foundation and the transport chassis. All major components, including solar panels, battery modules, inverters, diesel generators, and control cabinets, mount directly to this frame using shock-resistant fixings rated for the vibration and impact loads encountered on unsealed road travel.
A typical 100 kW hybrid solar skid measures approximately 12 metres in length by 2.4 metres in width, fitting comfortably within standard heavy vehicle transport dimensions and road transport regulations. Solar panels are mounted on adjustable racking systems welded to the skid’s structural frame, allowing field optimisation of panel angle. Battery enclosures and inverter cabinets bolt to reinforced structural sections of the frame, whilst diesel generator sets occupy dedicated mounting positions with vibration isolation. Weather-resistant enclosures protect all electronic components from dust ingress and temperature extremes common to remote Australian locations, with IP65+ ingress protection ratings preventing environmental contamination of sensitive electronics.
This fully integrated design approach eliminates the extensive site preparation work that typically adds weeks to conventional installation schedules. Where a traditional installation might require geotechnical surveys, foundation engineering analysis, civil construction, and lengthy approval processes before any power equipment arrives on site, skid systems need only relatively level ground and basic cable trenching for distribution connections to site loads. CDI Energy’s Rapid Solar Module takes this modularity concept further with solar arrays that deploy in hours rather than days, making these systems particularly suited to fast-moving exploration programs and time-critical project mobilisation.
Power Capacity and System Architecture
Skid-mounted hybrid systems scale across a wide range from 50 kW units suitable for small exploration camps and remote facility operations to 500 kW+ configurations powering construction villages and early-stage mining operations. The solar generation component typically provides between 30-60% of the system’s rated power capacity, with battery energy storage sized to handle evening peak loads and smooth transitions during periods when solar production declines below immediate load demands.
A representative 200 kW hybrid solar skid might incorporate 80 kW of solar PV capacity, 100 kWh of lithium battery storage, and a 200 kW diesel generator. During daylight hours, solar generation covers base loads whilst simultaneously charging the battery storage system. As solar production tapers in late afternoon, the battery discharges to meet continued demand without requiring generator startup. The diesel generator engages only during extended periods of high load demand or when battery state of charge reaches minimum thresholds, providing contingency power ensuring continuous operation.
This architecture achieves diesel offsets ranging from 40-70% depending on site-specific load profiles and local solar availability. For sites consuming 3,500 litres of diesel weekly under generator-only power, a properly sized hybrid system can reduce fuel consumption to 1,200-1,800 litres weekly, savings that accumulate rapidly when remote fuel delivery costs exceed $2.50 per litre plus transport surcharges.
The control system manages interactions between generation sources through sophisticated algorithms that prioritise renewable energy utilisation whilst maintaining supply reliability and power quality. When solar production exceeds current load demand, the excess energy charges the battery storage rather than being curtailed or wasted. Systems continuously forecast battery state of charge and adjust generator run times to ensure sufficient spinning reserve for sudden load increases.
Transport and Deployment Logistics
The mobility advantage of hybrid solar skid systems becomes most apparent during critical project mobilisation phases. A complete 150 kW system ships on two standard flatbed trucks (one carrying the primary skid with integrated solar arrays and battery modules, another transporting the diesel generator skid and auxiliary support equipment). For comparison, equivalent fixed installations require multiple 40-foot container shipments of individual racking components, electrical equipment, and construction materials, followed by weeks of labour-intensive on-site assembly and configuration.
Road transport to remote sites follows standard heavy vehicle regulations and road transport standards. The robust structural frame construction withstands vibration and shock loads encountered on unsealed access roads, protecting sensitive electronics through isolation mounting systems and reinforced protective enclosures. Systems routinely travel 500+ kilometres from Perth or other capital cities to Pilbara and Goldfields sites without requiring post-transport recalibration or component replacement.
Site placement requires only level areas with bearing capacity suitable for the skid’s weight distribution (typically 15-20 tonnes for a 200 kW unit). Many operators use compacted gravel pads or railway sleeper foundations rather than engineered concrete pads, further reducing site preparation time and cost compared to conventional installations. Hydraulic levelling jacks built into the skid frame allow precise positioning without requiring additional support structures or survey work.
Electrical commissioning involves connecting the skid to site distribution boards through weatherproof cable glands, configuring the control system for local load profiles and operational requirements, and testing protection systems to ensure proper operation. Experienced technicians complete this commissioning process in 8-12 hours for standard configurations. Systems can energise site loads the same day they arrive, impossible with traditional installations requiring weeks of site preparation and component assembly.
Operational Flexibility and Modular Expansion
Project power demands rarely remain static throughout their operational lifecycle. Exploration programs expand into development phases, construction camps grow as contractor numbers and equipment increase, and seasonal activities create variable loads across annual cycles. Hybrid solar skid systems accommodate these changes through modular expansion and rapid reconfiguration without requiring complete system redesign.
When power requirements increase, additional identical or larger skids connect in parallel to existing units through synchronised controls and protection systems. A site might start with a single 100 kW skid during initial drilling and exploration, add a second identical unit when camp accommodation doubles and equipment expands, then incorporate a larger 250 kW skid as ore processing or production activities begin. Each addition takes days rather than the months required for expanding fixed infrastructure.
This scalability proves particularly valuable for staged mining developments where capital allocation follows resource confirmation and feasibility studies. Rather than installing oversized power systems based on optimistic production forecasts, operators deploy capacity matching current needs and add generation capacity as actual project requirements materialise and are confirmed. This approach preserves working capital and maintains financial flexibility while ensuring adequate power for operations.
Relocation capability matters equally for contractor operations and project-based work. When exploration programs move to new target areas, or when construction phases are completed and camps demobilise, hybrid solar skid systems travel with the operation. The same unit that powered drilling at one tenement can be trucked 300 kilometres to energise activities at the next prospect. This reusability transforms power infrastructure from a sunk cost into a mobile asset that generates returns across multiple projects and operational locations.
Financial Models and Commercial Structures
The capital efficiency of transportable power systems creates opportunities for alternative commercial structures beyond conventional outright purchase. While ownership and purchase remain common for organisations with multiple projects, many operators access skid-mounted systems through Power Purchase Agreements or equipment leasing arrangements that eliminate large upfront capital investment.
Under a typical Power Purchase Agreement (PPA) structure, CDI Energy retains ownership and responsibility for the hybrid solar skid system whilst the customer pays only for electricity consumed, typically at rates 15-25% below diesel-only generation costs. The agreement includes all maintenance, fuel management, and system performance guarantees, converting unpredictable and variable power costs into fixed monthly expenses. Contract terms usually run 3-5 years with options for system relocation if project requirements change or new facilities require power.
This model particularly suits exploration companies and contractors working on fixed-price project agreements where cost certainty matters more than asset ownership. The avoided capital expenditure, often $400,000 to $800,000 for a 200 kW system, remains available for core business activities rather than being tied up in power infrastructure. Solar lease arrangements offer similar benefits with slightly different structures: the customer leases equipment for monthly payments, including service and maintenance, with options to purchase at lease end or return the system. These agreements typically run 5-7 years and work well for operations with predictable medium-term power needs but uncertain long-term site requirements.
Performance in Remote Australian Conditions
Western Australia’s remote regions present environmental challenges that test power equipment durability throughout extended operational periods. Ambient temperatures regularly exceed 45°C, dust storms reduce visibility to metres, and seasonal humidity during northern wet seasons accelerates corrosion and moisture ingress. Hybrid solar skid systems specifically designed for these conditions incorporate protection measures ensuring reliable operation regardless of weather extremes.
Battery enclosures include active thermal management systems that maintain cell temperatures within an optimal 15-35°C operating range despite ambient temperature extremes. Lithium iron phosphate battery chemistry, standard in most commercial skid systems, tolerates temperature variations better than other lithium technologies whilst providing cycle life exceeding 5,000 full depth-of-discharge cycles. This longevity matters significantly for systems that may operate at multiple sites over 10+ year service lives.
Solar panel mounting uses corrosion-resistant stainless steel hardware with locking mechanisms that maintain array alignment despite vibration from nearby heavy equipment or wind loading during cyclonic weather. Electrical enclosures achieve IP65 or higher ingress protection ratings, preventing dust accumulation on sensitive electronics whilst allowing necessary ventilation for heat dissipation and thermal management.
Generator sets integrate with the hybrid system through synchronisation controls that manage parallel operation and load sharing between sources. Modern diesel generators sized specifically for hybrid applications run at variable speeds, reducing fuel consumption during low-load periods whilst maintaining the fast response needed when solar production drops suddenly due to cloud cover or approaching weather systems. This variable speed operation extends service intervals and reduces maintenance requirements compared to fixed-speed generators running continuously.
Integration with Existing Site Infrastructure
Most remote sites already have some existing power infrastructure, including conventional generators, distribution switchboards, cabling to various loads, and, in many cases, partial renewable generation attempts. Hybrid solar skid systems integrate with these installations rather than requiring complete replacement, protecting prior capital investments whilst adding renewable generation capacity.
The integration process begins with comprehensive load profiling to understand power consumption patterns across daily cycles and seasonal variations. This data informs system sizing and control programming, ensuring the hybrid system can meet peak demands whilst optimising diesel offset during typical operations. For sites with highly variable loads, common in mining applications where large equipment cycles on and off unpredictably, battery capacity sizing becomes critical to maintaining supply quality without excessive generator runtime.
Connection to existing distribution typically occurs at the main switchboard through a synchronisation panel that manages power flow from multiple sources. Protection relays monitor voltage, frequency, and phase balance, isolating the hybrid system if parameters drift outside acceptable ranges. This protection prevents the hybrid system from back-feeding into failed generators or creating power quality issues that could damage sensitive electronic equipment and process controls.
Maintenance and Service Access
The self-contained nature of skid systems simplifies maintenance and service access compared to distributed installations where components spread across large areas or significant distances. Technicians access all major equipment from the skid platform, eliminating the need to travel between separate solar array locations, battery containers, and generator buildings during routine service visits.
Solar panels require periodic cleaning to maintain design output, particularly in dusty environments where soiling can reduce production by 15-20% if uncleaned over extended periods. The compact array layout allows cleaning crews to complete the work in hours rather than days, minimising disruption to operations. Automated monitoring systems track panel performance and alert operators when cleaning becomes necessary based on actual output degradation rather than arbitrary maintenance schedules.
Battery management systems continuously monitor cell voltages, temperatures, and state of charge, identifying developing issues before they cause failures. Lithium batteries require minimal maintenance compared to lead-acid alternatives (no watering, no equalisation charging, no specific gravity testing). Annual inspections verify electrical connections remain tight and thermal management systems function correctly.
Environmental and Sustainability Benefits
Remote operations face increasing pressure to reduce greenhouse gas emissions and demonstrate environmental responsibility. Hybrid solar skid systems provide measurable emissions reductions without compromising power reliability or requiring operational changes to site activities.
A 200 kW hybrid system displacing 60% of diesel consumption eliminates approximately 180 tonnes of CO2 equivalent emissions annually. For companies reporting under the National Greenhouse and Energy Reporting Scheme requirements, these reductions contribute directly to compliance obligations while potentially creating Australian Carbon Credit Units under the Emissions Reduction Fund.
The modular nature of skid systems allows organisations to stage emissions reductions as projects develop, demonstrating continuous improvement rather than requiring large one-time investments. This approach aligns with progressive environmental policies whilst maintaining financial flexibility.
Conclusion
Hybrid solar skid systems represent proven technology addressing fundamental challenges with remote project power supply. By packaging complete renewable generation plants into transportable modules, these systems eliminate traditional trade-offs between mobility and efficiency. Projects gain access to diesel offset percentages previously achievable only through permanent installations, whilst maintaining flexibility to relocate or scale capacity as requirements change.
The technology particularly suits Australia’s resource sector, where project timelines, geographical spread, and environmental conditions demand power solutions combining reliability with adaptability. From exploration phases through construction and into production operations, skid-mounted hybrids provide appropriately-sized generation capacity that moves with project value rather than becoming stranded assets when operations relocate.
For organisations evaluating power options for temporary sites, staged developments, or operations with uncertain long-term locations, CDI Energy offers feasibility assessments that model the total cost of ownership across different scenarios. These evaluations account for site-specific factors, including load profiles, solar resources, fuel logistics, and project timelines, to identify optimal system configurations and commercial structures. Our combination of Australian manufacturing, Clean Energy Council accreditation, and proven performance across 15MW+ of installed capacity positions us as the specialist in transportable renewable power for remote industrial applications.
For more information on hybrid solar skid system options, contact us to discuss your specific operational requirements and deployment timeline.