Remote mining operations, construction sites, and off-grid industrial facilities face a common challenge – reliable power generation is needed fast. Traditional solar installations can take months to engineer, procure, and commission. By that time, projects have burned through diesel fuel at $1.50-$2.00 per litre, racked up mobilisation costs for generator hire, and delayed critical operations.
Rapid deployment solar modules solve this problem. CDI Energy’s RSM system delivers containerised, pre-engineered solar arrays that deploy in under two weeks from order to energisation. The system arrives on-site ready to generate power – no lengthy design phases, no complex approvals, no extended construction schedules.
For project managers facing tight deadlines and operations teams managing fuel budgets, mobile solar power units deliver immediate diesel displacement without the typical lead times associated with conventional photovoltaic installations.
What Makes Rapid Deployment Solar Modules Different
Pre-Engineered Factory Integration vs Custom Builds
Standard solar installations follow a lengthy process: site assessment, custom engineering, procurement of individual components, shipping coordination, on-site assembly, electrical installation, and commissioning. This timeline typically spans 12-16 weeks for industrial-scale systems.
Rapid deployment solar modules eliminate most of these steps through pre-engineered, factory-integrated design. The RSM arrives as a complete power generation unit – PV modules, mounting structure, inverters, switchgear, and control systems integrated into a transportable package. This containerised solar generation approach removes the coordination complexity that causes delays in conventional installations.
Key Technical Specifications
Key technical specifications for the RSM system include power output from 10kW to 100kW configurations per module, high-efficiency monocrystalline silicon PV panels, pre-wired grid-forming or grid-following inverters, ground-mount or skid-mount options with adjustable tilt, IP65 protection for dusty mining environments, operating temperature range of -20°C to +50°C with passive thermal management, and deployment time of 7-14 days from order to energisation.
The system connects to existing site infrastructure through standardised electrical interfaces. For hybrid applications, mobile solar power units integrate directly with battery storage and diesel generators through AC coupling.
Technical Architecture of Rapid Solar Systems
The RSM uses a modular architecture that balances transportability with power density. Each unit fits within standard shipping dimensions (6m or 12m ISO container footprint) for road transport to remote sites without special permits.
Photovoltaic Array Configuration
The solar array uses bifacial monocrystalline modules rated at 400-550W each, depending on configuration. Modules mount to a hot-dip galvanised steel frame designed for wind loads up to 45 m/s and snow loads to 2.4 kPa – suitable for exposed sites across Australian conditions.
Tilt angle adjusts from 10° to 35° to optimise seasonal generation. For Pilbara mining sites at 22°S latitude, 20° tilt maximises annual energy yield. For construction projects in southern states, 30-35° tilt captures more winter generation when solar resource drops.
Power Conversion and Control Systems
String inverters or central inverters (depending on system size) convert DC power from the PV array to 400V three-phase AC output. Maximum power point tracking (MPPT) algorithms extract peak performance across varying irradiance and temperature conditions.
The inverter system includes grid-forming capability for stable off-grid voltage and frequency, grid-following mode for diesel generator or grid synchronisation, AS/NZS 4777 compliant anti-islanding protection, reactive power control from 0.8 leading to 0.8 lagging, and Modbus TCP/RTU communication interfaces for SCADA integration.
For sites requiring energy storage, the RSM connects to battery energy storage systems through AC coupling. This configuration allows independent operation of solar generation and battery storage, with coordinated control through the site microgrid controller.
Environmental Protection for Harsh Conditions
Mining and remote industrial sites expose equipment to extreme conditions – dust, heat, vibration, and UV radiation. The RSM addresses these through IP65-rated dust-tight enclosures protected against water jets, conformal coating sealing circuit boards against moisture and contamination, passive cooling with forced ventilation for inverters, UV-stabilised cables and connectors rated for outdoor exposure, and marine-grade hardware for coastal and high-humidity sites.
Deployment Process and Timeline
The two-week deployment timeline breaks down into distinct phases that demonstrate why rapid deployment solar modules represent a fundamentally different approach to remote power generation.
Days 1-3: Site Preparation
Site teams prepare a level gravel pad sized to the RSM footprint (typically 12m x 3m for a 50kW unit). The pad requires 100mm compacted crusher dust or road base with geotextile fabric underneath. No concrete foundations are necessary – the system uses ground screws or ballasted mounting for stability.
Electrical preparation involves installing a cable trench from the RSM location to the site switchboard. For a 50kW system, this requires 95mm² four-core armoured cable rated for 400V three-phase at 80A continuous current.
Days 4-5: System Delivery and Positioning
The RSM ships via truck to site. A standard crane or forklift positions the unit on the prepared pad. Ground screws (if used) install in 2-4 hours using a hydraulic driver. Ballasted systems simply require levelling and securing.
Days 6-8: Electrical Connection and Integration
Licensed electricians connect the RSM to site electrical infrastructure. This involves terminating the AC output cable to the site switchboard, installing protection and isolation equipment per AS/NZS 3000, connecting communication cables for monitoring and control, and integrating with existing generators or battery systems where applicable.
For hybrid solar-diesel remote power systems combining solar with diesel generators and battery storage, the integration requires configuring the microgrid controller to coordinate power sources. CDI Energy provides pre-programmed control logic for common site configurations.
Days 9-11: Commissioning and Testing
Commissioning verifies system performance and safety through insulation resistance testing (minimum 1 MΩ at 500V DC), earth continuity verification (maximum 0.5Ω loop impedance), inverter parameter configuration and protection settings, MPPT algorithm calibration for site conditions, communication system verification, and load testing at 25%, 50%, 75%, and 100% rated output.
Days 12-14: Handover and Training
Site personnel receive training on system operation, monitoring, and basic troubleshooting. This includes SCADA interface navigation and alarm response, daily visual inspection procedures, module cleaning protocols for dust accumulation, emergency shutdown procedures, and maintenance schedule overview. The system enters full operation with remote monitoring active, with CDI Energy providing ongoing performance monitoring and support from the Perth office.
Performance in Remote and Industrial Applications
Rapid deployment solar modules deliver measurable fuel savings and emissions reductions across diverse applications. Real-world performance data from field deployments validates the economic case for containerised solar generation across multiple sectors.
Mining Camp Power
A Goldfields mining operation deployed two 50kW RSM units to supplement diesel generators powering a 200-person camp. The site previously consumed 180,000 litres of diesel annually for baseload power generation.
Solar generation reduced diesel consumption by 65,000 litres per year – a 36% reduction in fuel use. At $1.80 per litre delivered to site, this saved $117,000 annually. The system also eliminated 173 tonnes of CO2 emissions per year. Peak solar generation occurs during the day when camp loads are highest (air conditioning, kitchen equipment, water treatment), and the RSM output matches this load profile, maximising diesel displacement without requiring battery storage.
Remote Telecommunications Sites
Telecommunications operators use mobile solar power units for remote tower sites. These locations typically rely on diesel generators running 24/7, consuming 15,000-25,000 litres annually per site.
A 10kW RSM system paired with 50kWh battery storage reduces diesel consumption by 80-90% at typical tower sites. Generator runtime drops from continuous operation to 2-4 hours per day for battery recharge during low solar periods.
The rapid deployment capability allows telecommunications providers to upgrade multiple sites quickly. One project deployed 12 RSM systems across regional Western Australia in eight weeks – a timeline impossible with conventional solar installations.
Construction Site Temporary Power
Construction projects require temporary power for 6-24 months. Hiring diesel generators for this duration costs $30,000-$60,000 per year for a 100kW load, plus fuel consumption of 200-300 litres per day.
Rapid deployment solar modules with battery storage provide an alternative. A 50kW RSM combined with 200kWh battery capacity and a 60kW backup generator delivers the same power reliability at 60-70% lower fuel consumption. The system relocates to the next project when construction completes, and this reusability spreads the capital cost across multiple projects, improving the economic case compared to generator hire.
Integration With Energy Storage and Hybrid Systems
Most remote sites require power 24 hours per day. Solar generation only occurs during daylight hours, creating a mismatch between generation and load. Energy storage bridges this gap.
AC-Coupled Architecture and Independent Optimisation
The RSM integrates with lithium-ion battery systems through AC coupling. This allows the solar inverter and battery inverter to operate independently. The solar system generates maximum power whenever irradiance is available. The battery system charges from excess solar generation and discharges to meet evening and night-time loads.
This independence simplifies control logic and improves reliability. If the battery system requires maintenance, solar generation continues to offset daytime diesel consumption. For hybrid solar-diesel remote power configurations, AC coupling provides the flexibility to add or service components without shutting down the entire microgrid.
Scalable Capacity for Growing Operations
Sites can add battery capacity incrementally as loads grow. A project might start with a 50kW RSM and 100kWh battery, then add another 100kWh when loads increase. The solar system continues operating without modification. Hybrid Solar Skid configurations extend this scalability by integrating solar charge controllers, battery inverters, and diesel genset control in transportable packages suited to evolving operational requirements.
Proven Reliability of AC-Coupled Architecture
AC coupling is the dominant architecture for utility-scale solar-plus-storage projects globally. The technology is mature, well-understood, and supported by multiple equipment vendors, reducing technical risk compared to emerging DC-coupled architectures. For remote operations where equipment failure translates directly to increased diesel costs, this proven reliability matters.
Economic Analysis and Payback Periods
Mobile solar power units compete economically with diesel generation in most remote applications. The analysis depends on diesel price, site load profile, and solar resource.
Base Case: Remote Mining Site
Consider a remote mining operation with 100kW average load, operating 24/7. Annual energy consumption is 876,000 kWh. Diesel generators provide all power at 0.35 kWh per litre fuel efficiency (typical for 200-300kW generators at 30-50% load).
A hybrid solar-diesel remote power system with 100kW solar, 400kWh battery storage, and existing diesel generators reduces fuel consumption by 55-65% depending on solar resource and load profile. Assuming 60% fuel displacement, annual fuel savings reach 1,501,800 litres at $1.80 per litre, delivering $2,703,240 in cost reduction. With system capital cost of $650,000, simple payback reaches 2.9 years. At $2.20 per litre (common for very remote sites), payback drops to 2.4 years.
Sensitivity to Solar Resource
Solar resource varies significantly across Australia. Darwin receives 5.8 peak sun hours per day annually, Alice Springs receives 6.4 peak sun hours, and Hobart receives 4.0 peak sun hours. A 50kW RSM in Alice Springs generates approximately 127,000 kWh annually, whilst the same system in Hobart generates 79,000 kWh – a 38% reduction affecting fuel displacement and payback proportionally. For marginal projects, solar resource assessment is critical. CDI Energy uses PVsyst modelling with site-specific irradiance data to predict generation accurately.
Maintenance Cost Advantages
Containerised solar generation systems require minimal maintenance compared to diesel generators. Annual maintenance costs typically run 1-2% of capital cost for solar (panel cleaning 2-4 times per year, annual inverter inspection, and electrical connection checks costing $3,000-$5,000 annually) versus 3-5% for diesel generators (oil changes every 250-500 hours, filter replacements, and major overhauls costing $15,000-$25,000 annually). Reduced maintenance costs improve total cost of ownership beyond fuel savings alone.
Site Requirements and Limitations
Suitable Applications
Rapid deployment solar modules work best when site conditions match system capabilities. Ideal applications include remote sites with diesel fuel costs above $1.50 per litre, operations requiring power for 6+ months (construction, exploration, temporary camps), sites with good solar access and minimal shading, locations accessible by standard truck transport, and projects requiring rapid commissioning such as emergency power or disaster relief.
Site Constraints and Assessment
Constraints include dense tree cover or significant terrain shading, sites above 2,000m elevation (reduced air density affects cooling), locations with heavy snow accumulation, and areas with extreme wind exposure requiring additional anchoring. For sites with challenging conditions, CDI Energy provides site assessment services across completed remote energy projects to verify feasibility before equipment mobilisation.
Conclusion
Rapid deployment solar modules address a critical gap in remote power supply – the need for clean, reliable generation without lengthy project timelines. The RSM delivers 10kW to 100kW solar capacity in under two weeks, providing immediate diesel displacement for mining operations, construction sites, telecommunications facilities, and temporary industrial power applications.
The pre-engineered, containerised solar generation design eliminates months of design, procurement, and construction time. Sites receive a complete power generation system – PV modules, inverters, mounting structure, and controls – ready to energise upon arrival. Integration with battery storage and diesel generators creates hybrid solar-diesel remote power microgrids that maintain 24/7 reliability whilst reducing fuel consumption by 55-65% in typical applications.
Economic analysis shows payback periods of 2-4 years for remote sites with diesel costs above $1.50 per litre. The system’s relocatable design spreads capital costs across multiple projects, improving returns for construction and temporary power applications. Mobile solar power units deliver proven performance with minimal project risk – the technology is mature, the deployment process is streamlined, and fuel savings are measurable from day one of operation.
To explore rapid solar deployment for remote power requirements, speak with CDI Energy’s rapid-deploy solar specialists or email info@cdienergy.com.au for a tailored site assessment and system recommendation.