1. 1. CAMISEA OPERATIONS August, 2007
2. 2. CAMISEA Operations Performance
3. 3. INDEX OPERATIONS EFFECTIVENESS COMPONENTS (KPIs) OVERALL EQUIPMENT EFFECTIVENESS (OEE) MALVINAS OEE PISCO OEE RELIABILITY BENCH SAFETY RECORDS
4. 4. OPERATIONS EFFECTIVENESS COMPONENTS (KPIs) Utilization / Production / Throughput (Gas) Availability Reliability Yield / Recovery (C3) (As a rule of thumb, World-class performers will only have losses of between 1.5 % to 2 % for all indicators) KPIs : Key Performance Indicators
5. 5. Overall Equipment Effectiveness (OEE) Objective method to link three performance indicators: Availability Throughput Yield / Recovery
6. 6. Overall Equipment Effectiveness (OEE) Can be expressed simply: OEE = Yield x Throughput x Availability The Maximun Theoretical World Class - OEE > 85%
7. 7. OEE = Availability X Throughput X Recovery (C3) (Plant Unit) (Gas) Hr Operatives Actual Throughput Actual yield (C3) Vs Vs Vs Hr Calendars Best Demonstrated Max Theoretical yield Rate (BDR) (for BDR) (96 %) (500 MMSCFD) (97.2%) Overall Equipment Effectiveness (OEE)
8. 8. Cry II Equim. Level; TC II TEx II Estabiliz. Equim. Level nC 1, 2, 3 Cry I Equim. Level; TC I TEx I Unit Level Unit Level Unit Level Plant Level AvailabilityAsset Plant Level Production Recovery (yield)X X Overall: O Equipment: E Effectiveness: E OEE = A x P x R Malvinas Operations
9. 9. PISCO OEE PLANT LEVEL / OVERALL OEE LPG FRACTIONATION UNIT TOPPING UNIT OEE 1 (Fract) OEE 2 (Topp) OVERALL OEE = (OEE 1 + OEE 2) 2 PISCO AxTxY AxTxY Fract Topp
10. 10. OEE 1 FRACTIONATION UNIT Actual Throughput Vs NGL received from Malvinas THROUGHPUT
11. 11. OEE 1 FRACTIONATION UNIT RECOVERY (Yield) C3/C4 Actual Yield Vs Design Yield (97.93% Vol) Actual Yield Vs Design Yield (99.21 % Vol) C3 C4
12. 12. OEE 1-2 FRACTIONATION AND TOPPING UNITS AVAILABILITY Hs Operatives (Hs Run) Vs Hs Calendars
13. 13. OEE 2 TOPPING UNIT Actual Throughput Vs (NGL received from Malvinas) x 0.54 THROUGHPUT 0.54 = design fraction of condensate in NGL from Malvinas
14. 14. Reliability Unplanned downtime (Reactive Maintenance) Maintenance Backlog Hs Operations Vs Hs Operations + Hs TMR (TMR: Total Maintenance Reactive) (Reliability; World Class performers > 98%)
15. 15. RELIABILITY 2006 MALVINAS 99% (Average of 24 main equipments: Turbocompressors,Turbogenerators, Turboexpanders, Pumps, Control System) PISCO 97.8% (Average of 20 main equipments: Turbogenerators, Pumps, Control System, Generators, Compressors)
16. 16. Availability Throughput Recovery OEE Jan-06 0.988 0.970 0.946 0.907 Feb-06 0.984 0.963 0.995 0.943 Mar-06 0.967 0.968 0.997 0.933 Apr-06 0.989 0.982 0.993 0.964 May-06 0.996 0.979 0.996 0.971 Jun-06 0.995 0.964 0.995 0.954 Jul-06 1.000 1.012 1.000 1.012 Aug-06 0.991 0.997 0.997 0.985 Sep-06 0.998 1.003 1.000 1.001 Oct-06 0.969 1.008 1.000 0.977 Nov-06 0.993 0.995 0.997 0.985 Dec-06 0.960 1.008 1.000 0.968 0.967Average Annual Malvinas Operations OEE 2006 Plant Level
17. 17. Malvinas Operations OEE 2007 Plant Level Availability Throughput Recovery Jan-07 0.999 1.011 1.000 1.010 Feb-07 1.000 1.013 1.000 1.013 Mar-07 0.832 0.753 0.956 0.599 TGP Event Apr-07 1.000 1.011 0.982 0.993 May-07 1.000 1.012 0.990 1.002 Jun-07 0.999 1.012 0.986 0.997 Jul-07 1.000 1.012 0.987 0.999 First seven months OEE 0.945
18. 18. Pisco Operations OEE 2006 Plant Level OEE Availability Throughput Quality OEE Availability Throughput Quality OEE GLOBAL Jan-06 0.990 0.950 0.990 0.931 0.990 0.920 0.990 0.902 0.916 Feb-06 1.000 0.920 0.990 0.911 0.990 0.890 0.940 0.828 0.870 Mar-06 1.000 0.940 0.990 0.931 1.000 0.860 0.910 0.783 0.857 Apr-06 1.000 0.990 1.000 0.990 1.000 0.950 0.960 0.912 0.951 May-06 1.000 0.970 1.000 0.970 1.000 0.940 0.940 0.884 0.927 Jun-06 1.000 0.970 1.000 0.970 1.000 0.940 0.940 0.884 0.927 Jul-06 1.000 0.990 1.000 0.990 1.000 0.960 0.950 0.912 0.951 Aug-06 1.000 0.990 1.000 0.990 1.000 0.920 0.980 0.902 0.946 Sep-06 1.000 0.980 1.000 0.980 1.000 0.930 0.970 0.902 0.941 Oct-06 0.990 0.990 0.990 0.970 0.990 0.930 0.990 0.911 0.941 Nov-06 0.990 0.980 0.990 0.960 0.990 0.940 0.970 0.903 0.932 Dec-06 1.000 0.990 1.000 0.990 0.940 0.950 0.980 0.875 0.933 Average Annual 0.965 Average Annual 0.883 0.924 Fractionation Topping
19. 19. Pisco Operations OEE 2007 Plant Level OEE Availability Throughput Quality OEE Availability Throughput Quality OEE GLOBAL Jan-07 1.000 0.989 0.997 0.985 0.987 1.000 0.970 0.958 0.971 Feb-07 0.928 0.983 0.994 0.907 0.906 1.000 0.960 0.870 0.888 Mar-07 0.980 0.945 0.988 0.915 1.000 1.000 0.964 0.964 0.939 Apr-07 0.982 0.972 0.987 0.942 0.998 1.000 0.963 0.961 0.952 May-07 1.000 0.990 0.991 0.980 1.000 0.938 0.943 0.884 0.932 Jun-07 0.991 0.983 0.991 0.966 0.995 0.941 0.942 0.882 0.924 Jul-07 0.988 0.988 0.991 0.967 0.997 0.961 0.932 0.893 0.930 First seven months 0.949 First seven months 0.920 0.934 Fractionation Topping
20. 20. BENCH
21. 21. The Reliability Involves Four Stable Operating Domains (Source: Ledet Enterprises, Houston Texas) OEE Mal 0.94 OEE Pis 0.93
22. 22. Maintenance Cost vs. Production reliability. Plants with the best overall equipment effectiveness tend to have the lowest maintenance cost and use systematic failure elimination, profit-centered maintenance and performance contracting. Maintenance Cost Vs. Production Reliability 2007 Malvinas Pisco
23. 23. Data from the 1998 and 2000 Solomon Associates Inc. surveys of the participating North and South American refining companies Availability Performance Comparison 90 91 92 93 94 95 96 97 98 99 100 1994 1996 1998 2000 2006 Availability RefineryMechanical Availability- U.S.Trend,% RefineryMechanical Availability- Pacesetters,% Refinery Operational Availability - U.S. Trend, % RefineryOperational Availability- Pacesetters,% AvailabilityMalvinas AvailabilityPisco
24. 24. As a rule of thumb, World-class performers will only have losses of between 1.5 % to 2 % for all indicators world-class performers are operating at > 85% of BDR Unavailability both timing and duration must be predictable. There must be no surprises Reliability; World Class performers > 98% Availability: world class performers > 96 %
25. 25. OIL & GAS JOURNAL / May 9, 2005 OEE Method Improves Condition Based Maintenance Aspen Technology Inc. , Houston Texas HYDROCARBON PROCESSING / January 2005 Achieving World-Class Operating Performance Polaris Veritas Inc. , Houston Texas Data from the 1998 and 2000 Solomon Associates Inc. surveys of the participating North and South American refining companies - Toward World Class Plant Availability Tom Ratajczak UOP LLC References
26. 26. SAFETY RECORDS
27. 27. SAFETY MALVINAS Frequency Index (FI) and Severity Index (SI) Januray 2006 - August 2007 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 FIAccum. 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 SIAccum. FI Accum 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.076 0.069 0.062 0.000 3.731 2.340 1.706 1.349 1.119 1.894 1.650 SI Accum 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.014 0.013 0.012 0.000 0.082 0.051 0.038 0.030 0.025 0.049 0.068 Jan-06 Feb-06 M ar-06 Apr-06 M ay- 06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 M ar-07 Apr-07 M ay-07 Jun-07 Jul-07 Aug-07
28. 28. SAFETY MALVINAS Man Hours Accumulated without Lost Days September 2006 - August 2007 152,130 0 200,000 400,000 600,000 800,000 1,000,000 1,200,000 1,400,000 1,600,000 1,800,000 2,000,000 ManHours MH Worked 119,188 140,611 137,530 165,401 133,332 134,700 159,360 158,760 155,124 152,222 162,622 156,150 MWAccum without Acc. 1,832,411 MWAccum without Acc. 140,611 278,141 443,542 576,874 MWAccum without Acc. 134,700 294,060 452,820 607,944 760,166 MWAccum without Acc. 152,130 308,280 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 760,16693 518,787 1'832,411 308,280
29. 29. SAFETY PISCO Frequency Index (FI) and Severity Index (SI) January 2006 - August 2007 0.00 0.75 1.50 2.25 3.00 3.75 4.50 5.25 6.00 6.75 SI 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 FI Severity Index 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Frequency Index 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Jan-06 Feb-06 M ar-06 Apr-06 M ay-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 M ar-07 Apr-07 M ay-07 Jun-07 Jul-07 Aug-07
30. 30. SAFETY PISCO Man Hours Accumulated without Lost Days January 2006 - August 2007 0 200,000 400,000 600,000 800,000 1,000,000 1,200,000 1,400,000 1,600,000 1,800,000 2,000,000 2,200,000 ManHours MHWor ked 78,781 71,576 85,368 86,304 95,066 96,616 92,136 101,347 90,080 90,539 94,462 93,218 97,369 87,807 97,591 88,255 98,700 85,685 91,202 85,101 MHAccumwithout Accidents 348,880 420,456 505,824 592,128 687,194 783,810 875,946 977,293 1,067,373 1,157,912 1,252,374 1,345,592 1,442,961 1,530,768 1,628,359 1,716,614 1,815,314 1,900,999 1,992,201 2,077,302 Jan-06 Feb-06 Mar -06 Apr -06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar -07 Apr -07 May-07 Jun-07 Jul-07 Aug-07 2077,302