CAMISEA

OPERATIONS

August, 2007
 CAMISEA

Operations Performance
 INDEX

• OPERATIONS EFFECTIVENESS COMPONENTS

(KPI’s)
• OVERALL EQUIPMENT EFFECTIVENESS (OEE)
– MALVINAS OEE
– PISCO OEE
• RELIABILITY
• BENCH
• SAFETY RECORDS
 OPERATIONS EFFECTIVENESS
COMPONENTS (KPI’s)

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)

KPI´s : Key Performance Indicators

 Overall Equipment Effectiveness
(OEE)
Objective method to link three performance indicators:

Availability

Throughput

Yield / Recovery
Overall Equipment Effectiveness
(OEE)

Can be expressed simply:

OEE = Yield x Throughput x Availability

The Maximun Theoretical

World Class - OEE > 85%

 Overall Equipment Effectiveness (OEE)

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%)
 Malvinas Operations
Plant Level Overall: O
Equipment: E
Estabiliz. Unit Level
Effectiveness: E
Equim. Level nC 1, 2, 3

OEE = A x P x R
Cry I Unit Level
Equim. Level; TC I
TEx I

Cry II Unit Level

Equim. Level; TC II
TEx II

Asset Plant Availability X Production X Recovery (yield)

Level
 PISCO OEE
PLANT LEVEL / OVERALL OEE
LPG FRACTIONATION UNIT OEE 1 (Fract)

TOPPING UNIT OEE 2 (Topp)

OVERALL OEE = (OEE 1 + OEE 2)

2
PISCO AxTxY AxTxY
Fract Topp
OEE 1 FRACTIONATION UNIT

THROUGHPUT

Actual Throughput

Vs

NGL received from Malvinas

OEE 1 FRACTIONATION UNIT

RECOVERY (Yield) C3/C4

Actual Yield
C3 Vs
Design Yield (97.93% Vol)

Actual Yield
C4 Vs
Design Yield (99.21 % Vol)
OEE 1-2 FRACTIONATION AND TOPPING UNITS

AVAILABILITY

Hs Operatives (Hs Run)

Vs

Hs Calendars
 OEE 2 TOPPING UNIT

THROUGHPUT

Actual Throughput

Vs

(NGL received from Malvinas) x 0.54

0.54 = design fraction of condensate in NGL from Malvinas

 Reliability
•Unplanned downtime (Reactive Maintenance)
•Maintenance Backlog

Hs Operations
Vs
Hs Operations + Hs TMR

(TMR: “Total Maintenance Reactive”)

(Reliability; “World Class performers” > 98%)
 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)
 Malvinas Operations – OEE 2006 Plant Level

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
Average Annual 0.967
 Malvinas Operations – OEE 2007
Plant Level

Availability Throughput Recovery OEE

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 0.945
 Pisco Operations – OEE 2006 – Plant Level
Fractionation Topping 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
 Pisco Operations – OEE 2007
Plant Level
Fractionation Topping 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
BENCH
The Reliability Involves Four Stable Operating Domains
(Source: Ledet Enterprises, Houston – Texas)

OEE Mal
0.94
OEE Pis
0.93
 Maintenance Cost Vs. Production Reliability
2007

Malvinas
Pisco

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.
 100
Availability Performance Comparison
99
98
97
Availability

96
95
94
93
92
91
90
1994 1996 1998 2000 2006
Refinery Mechanical Availability - U.S. Trend, % Refinery Mechanical Availability - P aces etters , %
Refinery Operational Availability - U.S. Trend, % Refinery Operational Availability - P aces etters , %
Availability Malvinas Availability P is co

Data from the 1998 and 2000 Solomon Associates Inc. surveys of the participating North and South
American refining companies
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

Reliability; “World Class performers” > 98%

Availability: “world class performers” > 96 %

Unavailability – both timing and duration – must be

predictable. There must be no surprises
 References

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
SAFETY RECORDS
 SAFETY MALVINAS

Frequency Index (FI) and Severity Index (SI)

Januray 2006 - August 2007
4.0 0.09

3.5 0.08
0.07
3.0
FI Accum.

SI Accum.
0.06
2.5
0.05
2.0
0.04
1.5
0.03
1.0 0.02
0.5 0.01
0.0 M ay- 0.00
J an-0 6 Feb -0 6 M ar-0 6 Ap r-0 6 J un-0 6 J ul-0 6 Aug -0 6 Sep -0 6 Oct-0 6 No v-0 6 Dec-0 6 J an-0 7 Feb -0 7 M ar-0 7 Ap r-0 7 M ay-0 7 J un-0 7 J ul-0 7 Aug -0 7
06

FI Accum 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 76 0 .0 6 9 0 .0 6 2 0 .0 0 0 3 .73 1 2 .3 4 0 1.70 6 1.3 4 9 1.119 1.8 9 4 1.6 50

SI Accum 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 14 0 .0 13 0 .0 12 0 .0 0 0 0 .0 8 2 0 .0 51 0 .0 3 8 0 .0 3 0 0 .0 2 5 0 .0 4 9 0 .0 6 8
 SAFETY MALVINAS

Man Hours Accumulated without Lost Days

September 2006 - August 2007
2,000,000
1'832,411
1,800,000
1,600,000
1,400,000
Man Hours

1,200,000
1,000,000
760,16693
800,000
518,787
600,000
308,280
400,000
200,000
152,130
0
Sep-06 Oct-06 Nov-06 Dec-06 J an-07 Feb-07 Mar-07 Apr-07 May-07 J un-07 J ul-07 Aug-07
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
MW Accum without Acc. 1,832,411
MW Accum without Acc. 140,611 278,141 443,542 576,874
MW Accum without Acc. 134,700 294,060 452,820 607,944 760,166
MW Accum without Acc. 152,130 308,280
 SAFETY PISCO

Frequency Index (FI) and Severity Index (SI)

January 2006 - August 2007
3.5
6.75
6.00 3.0
5.25
2.5
4.50
2.0
3.75

FI
SI

3.00 1.5
2.25
1.0
1.50
0.5
0.75
0.00 0.0
J a n-06 F e b-06 M a r-06 Apr-06 M a y-06 J un-06 J ul-06 Aug-06 S e p-06 Oc t-06 No v-06 De c -06 J a n-07 F e b-07 M a r-07 Apr-07 M a y-07 J un-07 J ul-07 Aug-07

S e ve rity Inde x 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
F re que nc y Inde x 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
 SAFETY PISCO

Man Hours Accumulated without Lost Days

January 2006 - August 2007
2,200,000
2’077,302
2,000,000
1,800,000
1,600,000
Man Hours

1,400,000
1,200,000
1,000,000
800,000
600,000
400,000
200,000
0
J an-06 Feb-06 Mar -06 Apr -06 May-06 J un-06 J ul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 J an-07 Feb-07 Mar -07 Apr -07 May-07 J un-07 J ul-07 Aug-07

MH Wor 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

MH Accum without 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