Customer stories
What customers in manufacturing, utilities and process industries needed, what was built, and what changed. Written with them and checked by them.
Each story below was written with the customer and checked by them before publication. Numbers are theirs unless marked as ours.
Nordfjord Paper: predictive maintenance across 14 mills
Sector: Pulp and paper. Practice areas: Predictive maintenance, lifecycle services.
Nordfjord runs 14 mills across Norway, Sweden and Finland. Unplanned stops on refiners and dryer sections were the largest single cause of lost production. Over two years Halden fitted sensors to around 900 assets and rolled out predictive maintenance mill by mill, starting with the equipment that had stopped each mill before.
Result: unplanned stops on monitored equipment fell by a little under half. "It paid for itself in the first unplanned stop it prevented," says Ingrid Solberg, VP Operations. The programme is written up in detail in the newsroom: three lessons from rolling out predictive maintenance across 40 sites and the customer story.
Lagos Water: energy management at scale
Sector: Utilities. Practice areas: Energy management, OT cyber security.
Pumping is the largest controllable cost for a water utility. Lagos Water asked for visibility first and savings second. Halden metered 60 pumping stations and treatment works, brought the data into one system and tuned pump scheduling against tariff periods.
Result: reported scope 2 emissions down 18 percent in the first year with no change in output, and an annual energy report that takes days to produce instead of weeks. "The reporting is what convinced our board," says Dr. Amara Okoye, Sustainability Lead.
Vale do Sol Chemicals: eleven years on site
Sector: Chemicals. Practice areas: Plant automation, lifecycle services.
Vale do Sol has had Halden engineers on site since a control system replacement eleven years ago. Since then the relationship has covered two safety system upgrades, a migration of the operator interfaces and an OT security assessment, all under one service contract.
Result: no unplanned stop attributable to the control system in the last six years. "They know it better than some of our own people," says Carlos Mendes, Plant Director.
A packaging manufacturer: upgrades over a weekend
Sector: Manufacturing. Practice areas: Plant automation.
A high-speed packaging plant with no tolerance for a mid-week stop. Three line upgrades, each built and tested at the Pune engineering centre, each cut over between Friday night and Monday morning with a rollback path that was never needed.
Result: "Every upgrade since you started has gone in over a weekend. The previous vendor needed a week."
Talk to sales about your plant.