At Viva Energy’s refinery in Geelong, Victoria, the Residual Catalytic Cracking Unit (RCCU) is the heart the of operations. Every five years, this vital asset undergoes a full shutdown and turnaround to reset its reliability, safety, and performance.
The 2025 RCCU turnaround is the largest in Viva’s refinery schedule and a pivotal moment in its operational future. More than just maintenance, this event marks the culmination of Viva Energy’s Gasoline Master Plan: the commissioning of a new ultra-low sulphur gasoline unit that will future-proof fuel production and emissions compliance.
UGL has played an important role in this multi-year journey. We've supported Viva Energy across brownfield modifications and greenfield construction, working hand-in-hand to plan, resource, and execute both shutdown and project scopes.
Success starts long before shutdown begins. UGL started planning over 12 months ago scoping works, developing workpacks, and sourcing long-lead items. To bring the very best to our client, we also engaged our Bennetts Green workshop's specialist fabrication capability to design and fabricate multiple long lead pressure vessels and exchangers. With over a decade of site experience at the Geelong refinery, we bring trusted relationships, skilled teams, and deep refinery knowledge.
UGL has supported Viva Energy across every phase — from brownfield modifications to shutdown execution. Mobilisation included ramping up our workforce, embedding our safety culture, and drawing on resources and expertise from across UGL.
“This shutdown represents a major moment in Viva Energy’s history,” says Michael Truter, UGL Operations Manager – Fuels, Refining and Engineering Services. “We’ve worked side by side with Viva Energy to get it right — planning early, executing safely, and bringing together teams from across UGL to deliver long-term reliability and sustainability for the refinery.”
Once complete, the RCCU turnaround will enable another five years of high-reliability operation. The new ultra-low sulphur gasoline unit represents a key environmental milestone, and positions Viva Energy’s refinery to meet evolving fuel standards and demand.
For UGL, it’s a proud example of end-to-end capability from planning and construction to shutdown execution. Together with Viva Energy, we’re laying the foundation for safe, reliable, and cleaner fuel production in Australia.