Fortescue iron ore ship in emergency rescue at Port Hedland

Whistleblowers say seven tugs had to pull the fully loaded FMG Nicola to safety and prevent a grounding that could have blocked the most important shipping channel in Australia.

Andrew Forrest launching the FMG Nicola in 2016.

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Fortescue triggered an emergency at the world’s biggest bulk export port when one of its fully loaded iron ore carriers broke down and almost blocked the shipping channel serving China’s commodity customers.

The incident was documented by whistleblowers who said seven tugs pulled the FMG Nicola to safety and prevented a grounding that had the potential to shut down Port Hedland for months.

Fortescue and Western Australia’s Pilbara Ports Authority remained silent on the emergency until contacted by The Australian.

There are growing concerns about the operation and management of Port Hedland among senior figures in the ports and resources industries, who said the FMG Nicola emergency and other unreported incidents were cause for alarm.

Bulk iron ore carriers at Port Hedland.

Experts advising port users have warned that a “hard” grounding in the shipping channel would take at least six months to clear and deal a huge blow to the terms of trade.

BHP and Gina Rinehart’s Roy Hill both use Port Hedland. BHP’s tug fleet played a key role in the rescue of the FMG Nicola.

It is understood BHP has been in talks with the port authority about channel works to reduce ­operational risk, and that the port authority is asking other users to boost the capability of their tug fleets.

There are conflicting reports on whether the FMG Nicola – named after Nicola Forrest and launched in 2016 – strayed outside the channel in the February 7 emergency.

Sources with knowledge of the incident, who asked not to be identified, said the FMG Nicola was outside the shipping channel and may have hit the bottom, if not briefly grounded.

But Fortescue maintains the FMG Nicola did not leave the shipping channel after a main engine failure and loss of rudder control while leaving port.

It was loaded with about 260,000 tonnes of iron ore and under towage by three Fortescue tugs while navigating through the channel outside the harbour when the main engine failed.

The vessel lost rudder control due to the size of the cargo and a harbour emergency was declared. Four other tugs were called in as part of the rescue.

“Fortescue takes the safety of its people, vessels and operations extremely seriously,” a company spokesman said.

“This incident highlights the effectiveness of our emergency protocols and the exceptional skill of our marine crews in managing unexpected events safely and swiftly.

Freight wagons filled with iron ore travel along rail tracks near Port Hedland. Picture: Getty Images

“Port Hedland plays a critical role in supporting WA’s iron ore exports. It is managed to a world-class standard, with regular consultation among all terminal users to ensure safe and seamless co-­ordination.”

BHP’s tug fleet – including the Iron Brolga, Iron Corella and RT (roto-tug) Atlantis – participated in the rescue.

The port authority declined to answer questions about whether the carrier strayed outside the narrow shipping channel and into shallower territory, except to confirm that the FMG Nicola was stabilised, anchored and repaired. “The vessel had not grounded.”

Pilbara Ports denied there had been any recent groundings, in response to questions from The Australian.

“In 2025, a vessel suffered a main engine and steering failure during passage of zones 4/5,” the authority said in a statement.

“New operating procedures have been introduced and include a reduction in speed-over-ground for vessels in zones 4/5 of the channel, amendment of the ­escort towage strategy and further refinement of emergency training.”

A report was made to the Australian Maritime Safety Authority, and the Australian Transport Safety Bureau was informed but determined that no investigation was needed.

Last Friday, a marine safety bulletin describing a series of vessel emergencies at Port Hedland in the first six months of 2025 was issued.

There were nine incidents involving engine failures or other problems. In six cases, vessel emergencies were declared and additional tugs deployed. In another, berthing was aborted and the vessel returned to anchor offshore.

Gina Rinehart’s Roy Hill and BHP both use Port Hedland. Picture: Colin Murty

Pilbara Ports declined to give details of the vessels, owners or the dates of the incidents.

It followed up last Friday’s safety bulletin with new rules on emergency steering and vessel preparedness for using the iron ore export epicentre.

In 2022, a vessel made minimal contact with the edge of the channel after a steering system malfunction.

Port Hedland is under growing pressure with iron ore exports increasing and hundreds of ships per year entering and leaving the relatively narrow and shallow channel with big tidal variations.

Exports have increased to about 560 million tonnes, from 510 million tonnes in 2018-19, with multiple iron ore carriers scheduled to leave each high tide.

BHP has been sitting on plans to boost iron ore production to 330 million tonnes a year from the Pilbara in light of market factors.

It sold 287.7 million tonnes exported from Port Hedland in 2023-24 and has said it can increase that to 305 million tonnes in the medium term at a low cost.

Originally published as Fortescue iron ore ship in emergency rescue at Port Hedland