The Challenge

Shutdowns demand precision, planning, and zero delays.

For this project, our client required over 350 tools as part of a broader operation involving thousands of pieces of equipment that needed to be tracked, verified, and ready for use.

With multiple crews working simultaneously and tight timelines in place, even small inefficiencies could have a flow-on effect across the entire shutdown.

The objective was clear: deliver a tooling setup that was not only complete, but easy to manage, verify, and deploy on site.

Our Approach

Understanding the Scope

We began with a detailed review of the tooling requirements, working closely with the client to understand not just what was needed but how it would be used on site.

From there, we:

• Assessed availability across both branches
• Identified items requiring servicing or certification
• Coordinated with trusted suppliers for additional equipment
• Considered how tools would be distributed across crews and work fronts

This upfront planning ensured the tooling package aligned with real-world conditions, not just a checklist.

Building the Right Tooling Package

This shutdown required a carefully considered mix of equipment, tailored to the nature of the work and site conditions.

A key component was the use of:

• Air wrench pumps and hydraulic systems: selected due to site constraints where electrical power wasn’t always practical or permitted.
• Hoses and cassettes: enabling efficient, repeatable bolting across multiple work areas.
• Pneumatic and battery-powered nutrunners: providing flexibility depending on access and application.
• Flange alignment kits: essential for precision during reassembly.
• Spring balances: supporting the safe handling of heavy cassettes and actuators (often up to 50kg), reducing strain and improving control.
• Slogging spanners and sockets: covering manual applications where required.
• Hydraulic wrenches and hydro kits: rounding out the setup for varying bolt sizes and torque requirements

As the scope of work has grown over time, so too has the level of support the client relies on from WATT.

Built on previous shutdowns, this tooling package reflects a deep understanding of our client’s requirements.

This allowed us to deliver a setup that was not only fit for purpose but trusted from the outset.

 

Preparation & Readiness

On a shutdown, preparation is everything.

Every piece of equipment was:

• Serviced, calibrated, and site-ready
• Matched with the correct documentation
• Grouped logically for efficient inspection and deployment

On many sites, inspection teams aren’t operating the tools themselves. Instead, they’re verifying that certification matches each item.

By aligning tools with their documentation and presenting them in a structured way, we helped streamline this process significantly.

Built for Real-World Conditions

No project ever runs perfectly to plan, and tooling needs to account for that.

To support continuity on site, we:

• Supplied contingency equipment to cover potential failures
• Guaranteed fast turnaround times on servicing and repairs
• Provided pre-prepared backup options to avoid reinspection delays

Because introducing a new tool mid-shutdown can trigger reinspection requirements, having pre-certified backups ready to go made a measurable difference to keeping operations smooth.

The Outcome

• 350+ tools prepared, delivered, and ready for use
• Streamlined inspection and verification process
• Reduced administrative burden for the client team
• Backup solutions in place to minimise downtime

Most importantly, we helped remove friction from a complex shutdown — allowing the client to focus on execution, not coordination.

The WATT Difference

At WATT, we don’t just supply tools. We support the system around them.

We understand the realities of shutdown work: tight timelines, multiple crews, and no room for delays.

That’s why we focus on delivering tooling solutions that are not only technically sound — but practical, reliable, and easy to manage on site.

Got a project you need help with? Contact us.