2025 Cracker Shutdown — Viva Energy Geelong Refinery
2025 Cracker Shutdown — Viva Energy Geelong Refinery
In 2025, Viva Energy undertook a major planned shutdown at the Geelong Refinery focused on the Residual Catalytic Cracking Unit (RCCU), commonly known as the “cracker.” This turnaround was publicly reported as Viva Energy’s largest shutdown event, running for approximately 10 weeks from August through mid-October 2025, supporting critical maintenance and infrastructure upgrades aligned with the Gasoline Master Plan (GMP).
Successful Craneage & Rigging Delivery – Delivered by McKay United
McKay United was engaged to provide specialist craneage and rigging services to support safe, efficient execution of shutdown works within one of the refinery’s most complex operating areas.
Sector
Infrastructure — Bridges & Roads
Client
Viva Energy Geelong Refinery
Location
Geelong, Victoria, Australia
Completion
December 2025
Heavy lift craneage for shutdown maintenance activities. Heat exchanger and bundle removals/installations. Vessel, column, and internal component handling. Pipe spool, structural steel, and module lifts. Rotating equipment change-outs (motors, pumps, gearboxes). Shutdown enablement lifts (temporary works, access, tooling). All works were completed under tight SIMOPS conditions within active brownfield refinery infrastructure.
Congested work zones with restricted crane positioning. High-volume lift sequencing tied directly to the shutdown critical path. Multiple contractors operating simultaneously under SIMOPS controls. Strict refinery safety, permit, and exclusion requirements. Weather-sensitive lift windows impacting crane operations. Schedule pressure requiring consistent performance across shifts.
McKay United achieved the following key outcomes: Zero Lost Time Injuries (LTI-free execution) across all craneage and rigging activities. Safe delivery of high-volume lifting in a high-risk brownfield refinery environment. Strong schedule performance supporting refinery restart milestones. Completion aligned with the broader Gasoline Master Plan (GMP) program timeline. Effective coordination across multiple shutdown contractors and SIMOPS constraints. This performance reinforced McKay United’s reputation as a trusted provider for high-consequence industrial shutdown works.
Early engineering and lock-in of critical lifts reduces turnaround risk Strong laydown and lift path control prevents unnecessary rehandling. Standard rigging systems improve safety and repeatability across shifts. SIMOPS discipline is essential in congested refinery environments. Weather and contingency planning protects shutdown productivity.
With zero LTIs, strong schedule adherence, and successful alignment with the Gasoline Master Plan, McKay United continues to be a trusted partner for Australia’s energy and heavy industrial sector.
Planning & Engineering
McKay United’s success was driven by detailed front-end planning and disciplined engineered execution.
Lift Governance & Engineering
- Lift categorisation (routine, intermediate, critical)
- Engineered lift studies for constrained and high-risk picks
- Rigging design including CoG verification, sling configurations, and landing plans
Shutdown Readiness
- Pre-shutdown crane pad and travel route verification
- Dedicated laydown zoning to minimise double-handling
- Confirmation of lifting points and equipment weights prior to execution
Safety & Compliance
- Refinery-aligned lift permit systems and exclusion controls
- Daily pre-start briefings and SIMOPS coordination
- Lift supervisors and spotters assigned for blind and critical lifts
Execution highlights
Lift accuracy
Integrated daily planning with Viva Energy shutdown coordination teams to ensure every lift aligned with the shutdown schedule. Hold-point verification completed for all critical lifts, including weather, permits and exclusion zones.
Weight
Lift planning and rigging methodology were developed to safely manage heavy shutdown components within crane and ground bearing capacity limits. Standardised rigging configurations ensured loads were handled within engineered lifting parameters.
Efficiency
48–72 hour lift look-ahead scheduling to protect the shutdown critical path. Pre-rigging in controlled zones to minimise hook time within process areas. Standardised rigging kits used to improve consistency and streamline crane operations across crews.
Environmental
Careful lift planning and reduced crane operating time helped minimise unnecessary engine idling and emissions. Controlled work zones supported compliance with refinery environmental management requirements.
