Valero Refining Texas LP Bill Greehey Refinery     Corpus Christi   Refinery Energy Initiatives
Valero Overview• Valero Energy Corporation is a Fortune 500 company based in San Antonio,and is North America’s largest in...
Historic Energy Activities• Steam Trap Program– Surveys completed every one to two years– Costs associated with improperly...
Historic Energy Activities• Monthly Energy Business Unit Review– Monthly teleconference held with all refineries, corporat...
Corporate Energy Stewardship Program                           Overview• Initiated in 2007• Involves all refineries in cor...
Corporate Energy Stewardship Program                          Energy Models• Consultant used to build energy input models ...
Corporate Energy Stewardship Program            Dynamic Energy Targets• Next phase of program involves setting dynamic ene...
Corporate Energy Stewardship Program Results                         to Date• Current captured savings are approximately t...
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Valero refinery energy

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Valero Overview

• Valero Energy Corporation is a Fortune 500 companybased in San Antonio, and is North America’s largestindependent petroleum refiner and marketer. Valerosupplies fuel and products that improve people’s liveswith 15 refineries and 10 ethanol plants stretchingfrom California to Canada to the Caribbean.

• Valero’s efforts in alternative energy range fromproduction of corn ethanol to wind energy toinvestments in emerging bio‐fuels development.

• Valero’s company‐owned retail Corner Stores offercustomers fast, friendly service in a safe and clean environment



Bill Greehey RefineryOverview

• Valero commissioned the grass‐roots Corpus Christi refinery in 1983, nowreferred to as the Bill Greehey Refinery West Plant

• In 2001 Valero acquired a 115,000 BPD refinery, now referred to asthe Bill Greehey Refinery East Plant

• East and West plant facilities have a total feedstock throughput capacityof about 315,000 BPD

• Refinery has three independent steam systems and two fuel gas systems– East and West fuel gas systems receive gas from a third party supplier inaddition to internally produced gasses

• Hydrogen is purchased from two outside suppliers as well as producedinternally

– East, West and Valero Three Rivers Refinery hydrogen systems connect viathird party supplier networks as well as Valero owned East/West tie line

• The refinery purchases power as well as produces power from internallyproduced waste energy

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Valero refinery energy

  1. 1. Valero Refining Texas LP Bill Greehey Refinery Corpus Christi Refinery Energy Initiatives
  2. 2. Valero Overview• Valero Energy Corporation is a Fortune 500 company based in San Antonio,and is North America’s largest independent petroleum refiner and marketer.Valerosupplies fuel and products that improve people’s lives with 15 refineries and 10 ethanol plants stretching from California to Canada to the Caribbean.• Valero’s efforts in alternative energy range from production of corn ethanol to wind energy toinvestments in emerging bio‐fuels development.• Valero’s company‐owned retail Corner Stores offer customers fast, friendly service in a safe and cleanenvironment Bill Greehey Refinery Overview• Valero commissioned the grass‐roots Corpus Christi refinery in 1983, now referred to as the BillGreehey Refinery West Plant• In 2001 Valero acquired a 115,000 BPD refinery, now referred to as the Bill Greehey Refinery East Plant• East and West plant facilities have a total feedstock throughput capacity of about 315,000 BPD• Refinery has three independent steam systems and two fuel gas systems– East and West fuel gas systems receive gas from a third party supplier in addition to internallyproduced gasses• Hydrogen is purchased from two outside suppliers as well as produced internally– East, West and Valero Three Rivers Refinery hydrogen systems connect via third party suppliernetworks as well as Valero owned East/West tie line• The refinery purchases power as well as produces power from internally produced waste energy
  3. 3. Historic Energy Activities• Steam Trap Program– Surveys completed every one to two years– Costs associated with improperly functioning traps are quantified and repairs scheduled– Historic failure rate has been 3.5%• Corporate Energy Scorecard– Program has been in place since 2006– Individual items reported include such things as Solomon EII, heater and boiler excess air and stacktemperatures, Crude Unit heater approach temperatures, steam balancing and venting, hot rundowngiveaway, slop reprocessing, amine strengths and loadings and ammonia content of stripped sourwaters– Individual items are weighted and an overall score assigned• Weekly Fired Heater Report– Program in place since 2007– Excess air and stack temperature targets have been established for all major fired furnaces and boilers– Reports submitted weekly with actual values and deviations from targets– Costs of deviations from target are calculated based on current fuel values– Results as well as actions required to correct deviations are reviewed with Corporate OperationsManagement weekly• Leak Detection and Repair Programs– Emphasize operating practice of reporting leaks for prompt repair– Follow up with consultant surveys
  4. 4. Historic Energy Activities• Monthly Energy Business Unit Review– Monthly teleconference held with all refineries, corporate energy personnel and corporate operationsmanagement– Energy Scorecards, Weekly Heater Reports and results of Energy Stewardship Program are reviewed– Provides a forum for lessons learned to be communicated across the corporation• Solomon Energy Intensity Index, EII– Calculated monthly and reported to corporate with other Solomon indicators• Capital Project Design Reviews– All capital projects subject to design review that includes optimizing energy consumption accordingto corporate return on capital requirements• Energy Coordinator– A senior member of the engineering staff also functions as the Refinery Energy Coordinator– Responsibilities include maintenance of Energy Scorecard, Weekly Heater Reports and Solomon EIIcalculation• Utility Balances– Spreadsheet based tools retrieving information from the refinery historian are available for technicaland operations management use in monitoring and balancing systems– Real time balance information also displayed for operations staff use– Steam, fuel gas, power and hydrogen systems are included
  5. 5. Corporate Energy Stewardship Program Overview• Initiated in 2007• Involves all refineries in corporation• Introduced to Bill Greehey Refinery in 2009 Corporate Energy Stewardship Program Basics• Program begins with an energy gap review conducted by plant personnel, corporate personnel and anenergy consultant• All units and utility systems are reviewed• Items from gap reviews are approved and entered into the Energy Log• The Energy Log is spreadsheet based and contains information on the item, anticipatedbenefits, responsible parties and schedule for review and/or implementation• Priority is given to non‐capital items
  6. 6. Corporate Energy Stewardship Program Energy Models• Consultant used to build energy input models for all units.• Past best performance is determined and used as the basis for current static targets.• This information is presented graphically and in tabular format and is reviewed bymanagement, operations and engineering daily Corporate Energy Stewardship Program Energy Team• Refinery Energy Team was formed• Members of the team include Operations Director, Complex Managers, Engineering Director, EnergyCoordinator, Technical Services Manager and others as needed• Makeup of team differed from other Valero Refineries in that team was made up of individuals withauthority to implement actions quickly• Weekly team meetings are held where Energy Log, Weekly Heater Report and other energy relateditems are reported and reviewed
  7. 7. Corporate Energy Stewardship Program Dynamic Energy Targets• Next phase of program involves setting dynamic energy targets for individual units and refinery as awhole• Consultant utilized to regress plant data to determine energy consumption correlations according tounit conditions, severities, etc• This phase of program currently being prepared for rollout Corporate Energy Stewardship Program Energy Dashboards• Energy Dashboards are being constructed to display real time information on monitors in all controlrooms, individual desk tops and the corporate office• Dashboards have drill down capabilities to determine what items are not achieving targets on a unitand energy source basis• Deviations from target are coded to show magnitude of deviation• Exception reports are issued
  8. 8. Corporate Energy Stewardship Program Results to Date• Current captured savings are approximately twice the initial estimates and have provideda return on investment four times the minimum required by the corporation• Further savings are anticipated as the program progresses

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