Valero Energy Corporation Bill Greehey Refinery Corpus Christi

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
independent petroleum refiner and marketer. Valero
supplies 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 to
investments in emerging bio‐fuels development.
• Valero’s company‐owned retail Corner Stores offer
customers fast, friendly service in a safe and clean
environment

Bill Greehey Refinery
Overview
• Valero commissioned the grass‐roots Corpus Christi refinery in 1983, now
referred to as the Bill Greehey 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 internally produced 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 supplier networks as well as Valero owned East/West tie line
• The refinery purchases power as well as produces power from internally
produced waste energy

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 stack
temperatures, Crude Unit heater approach temperatures, steam balancing and venting, hot rundown
giveaway, slop reprocessing, amine strengths and loadings and ammonia content of stripped sour waters
– 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 Operations
Management weekly
• Leak Detection and Repair Programs
– Emphasize operating practice of reporting leaks for prompt repair
– Follow up with consultant surveys

Historic Energy Activities
• Monthly Energy Business Unit Review
– Monthly teleconference held with all refineries, corporate energy personnel and corporate operations
management
– 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 according to
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 EII
calculation
• Utility Balances
– Spreadsheet based tools retrieving information from the refinery historian are available for technical and
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

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 an energy 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, anticipated
benefits, responsible parties and schedule for
review and/or implementation
• Priority is given to non‐capital items

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 by
management, 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, Energy
Coordinator, Technical Services Manager and others as
needed
• Makeup of team differed from other Valero Refineries
in that team was made up of individuals with authority
to implement actions quickly
• Weekly team meetings are held where Energy Log,
Weekly Heater Report and other energy related items
are reported and reviewed

Corporate Energy Stewardship Program
Dynamic Energy Targets
• Next phase of program involves setting
dynamic energy targets for individual units
and refinery as a whole
• Consultant utilized to regress plant data to
determine energy consumption correlations
according to unit 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
control rooms, individual desk tops and the
corporate office
• Dashboards have drill down capabilities to
determine what items are not achieving targets
on a unit and energy source basis
• Deviations from target are coded to show
magnitude of deviation
• Exception reports are issued

Corporate Energy Stewardship Program
Results to Date
• Current captured savings are approximately
twice the initial estimates and have provided
a return on investment four times the
minimum required by the corporation
• Further savings are anticipated as the
program progresses

Questions?