LFI Tool - PD-HX-REP-003 Rev.01

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PDO FEED OFFICE
Learnings from Incidents (LFI) Tool
Document No: FEED-HX-REP-003
01 6/17/2019 Issued for Approved UEFH3/SE UEFH/MD UEFH/MD
Rev. Date Description Originator Checker Approver

(Ref.Ind / Std.Initial) (Ref.Ind / Std.Initial) (Ref.Ind / Std.Initial)
Format No:FEED-QM-FOM-023, Rev.06

1. Background:
This Learnings from Incidents (LFI) Tool summarizes all agreed and CFDH endorsed learnings from PDO AIPS incidents
recorded in the AIPS Databook. It consists of incidents that happened between 2012-2017. Each record consists of Incident
reference number for easy referencing in order to search quickly in AIPS Databook and other issued reports
PDO201904100035 (Ref 3) . Furthermore, a short description of the incident is provided as well as the actual and potential
consequence of it. Key are the key learnings of the specific incident and each learning is categorised into 3 types such as
Design Integrity, Technical Integrity and Operation Integrity. Also the key disciplines assigned to each learning in order to
take responsibility to embed it in the project lifecycle.
In total approx. 380 learnings have been derived from about 122 incidents. For 2012, the learnings are coming from 11 Tier
1 incidents; for 2013 from 13 Tier 1, 1 Tier 2 and 2 HiPo incidents; for 2014 from 22 Tier 1 incidents; from 2015 from 11
Tier 1, 7 Tier 2 and 5 HiPo incidents; for 2016 from 8 Tier 1, 8 Tier 2 and 5 HiPo incidents; and for 2017 from 13 Tier 1, 11
Tier 2 and 5 HiPo incidents. More information on the incident, can be found in the AIPS Databook.
This LFI Tool will be continuously updated as and when the incidents for later years learnings are reviewed and endorsed by
the CFDHs.
2. Objective:
The main objective is to incorporate the applicable learnings from the past PDO AIPS incidents into the project life cycle
such that the same incidents shall not reoccur. This to demonstrate one of the statement of fitness element as part of the
AIPSM compliance.
Template No: FEED-HX-REP-003 Rev.01 Page 2 of 26

3. Instructions during Design Stage: Detailed information is provided in PR-2050, however the key instructions are
specified below.
BfD: During this stage each learning related to all categories (Design Integrity, Technical Integrity & Operation Integrity) in
LFI tool to review the applicability to the project considering all phases of the project life cycle (till handover to operations).
Refer to LFI Tool column "Applicable to Project" - Mention "Yes or No" and no need to review the pre-screened "NA"
learnings. At this stage the requirement is to screen the applicable learnings by end of the BfD and ensure any conceptual
or basic design related learnings as applicable are embedded in the design. The LFI screening sheet has to be signed by
relevant TA2s.
FEED: The applicable LFIs shall be reviewed which was done during BfD stage and ensure the screening done during BfD
stage is updated (if required) at the beginning of the FEED and shall be completed on or before HAZID. The compliance
inputs provided during BfD to be updated if any and further inputs has to be provided on or before HAZOP and final
compliance inputs and sign-off to be completed on or before IPF.
FEED+DD/DD: The applicable LFIs shall be reviewed during FEED+DD/DD stage and ensure that the previous screening
done is correct. All the relevant learnings are screened at the beginning of the FEED+DD/DD projects and this shall be
completed on or before HAZID. The compliance inputs provided during previous stages to be verified/updated (including
document numbers) and further inputs has to be provided/updated on or before HAZOP and final compliance inputs and
sign-off to be completed once all learnings are incorporated in "Approved" documents and the status (Open/Closed) to be
updated accordingly for the applicable learnings.
Post DD: The LFIs which are applicable to construction, pre-commissioning and commissioning shall be further update at
this stage by PDO construction and commissioning team along with Project Management Team. The Project Team shall
ensure the completion of LFI tool as part of the preparation of Statement of Fitness.
4. Deviation from Learnings:

As these learnings are from the PDO real incidents, it is very important to review and incorporate all relevant/applicable
learnings in the relevant project phase as part of the AIPSM compliance. However, if the applicable learning is not
incorporated for any reasons, a justification shall be included in the LFI sheet itself to demonstrate why the learning is not
been implemented. The relevant discipline TA2 is accountable to justify the rationale of not incorporating the relevant
learnings in the design.

5. Notes:
1. Each and every learning is assigned to various disciplines, responsible to provide the compliance demonstration as part
of the LFI standardisation process and which has been agreed with the respective leads.
2. During pre-screening process, those LFIs falls under the following category are screened out by indicating as "Not
Applicable (NA)":
(i) Learnings which are repeated (duplicated learnings);
(ii) Learnings which are completely belongs or can only be demonstrated by non-Project or non-Engineering team (e.g;
Operations)
(iii) Learnings which are already captured in the PDO standards & DEPs which are followed in PDO projects.
It is expected that the learnings which are already captured in relevant PDO standards & DEPs are to be implemented by
default as the design to be followed as per codes and standards in first place. The learnings belongs or can only be
demonstrate/review by non-project or non-Engineering team (e,g; operations) is not required to demonstrate/review
during design phase and separate demonstration process is manage by those relevant units/departments.
3. The status (Open/Closed) has to be mentioned at the end of DD stage (before post DD) of the project, where the
construction, pre-commissioning and commissioning scope is handled by others. The LFIs related to construction, pre-
commissioning and commissioning scope to kept as open and these LFIs shall be further updated at this stage by PDO
construction and commissioning team along with Project Management Team.
4. Compliance Demonstration Phase in LFI Tool: Post DD indicates pre-commissioning, commissioning, construction phase
etc. till handover to operations. The procurement related LFI shall be considered as part of the DD.
5. In general, the LFI compliance demonstration is part of the AI-PSM Compliance Report and are not required to be
produced as the standalone report in projects. LFI compliance demonstration worksheet is to be place as one of the
appendix of the AI-PSM Compliance Report.
6. At BfD & FEED stage, the sign-off of LFI compliance demonstration can be supported with reference to first revision
(Rev.01) issued documents. However for the FEED+DD/DD projects, the sign-off of the LFI demonstration shall be
completed once all the approved vendor/ owner documents are issued in Assai by the respective disciplines. At
FEED+DD/DD stage, all the documents referenced in the LFI tool for demonstration shall be through final approved
(vendor/owner) documents only.
6. References:
1. AIPSM Incident Databook - http://portal.corp.pdo.om/solutions/LKB/MSE/AIPSM/Pages/HomePage.aspx
2. PR 2050 - FEED Office Demonstration of AI-PSM Compliance Procedure
3. Document No: PDO201904100035 - Learning from Incidents A summary Report of Learnings from PDO AIPS Events
(2012-2017)

Project ID:
Project Name:
Project Stage:
Document No. & Rev.No:
Date:
Learning from Incidents (LFI) Tool
Applicable to Compliance Accountable Accountable LFI Compliance Document Evidence for Status
Learning Incident Project (All LFI Compliance Demonstration for
Key Learnings Demonstration Discipline 1 for Discipline 2 for Accountable Discipline 1 & 2 (Closed or
S.No. Reference ID Phases) Accountable Discipline 1 & 2
Phase the Learning the Learning (Document Description & Number) Open)
(Yes or No)
Accountable Discipline 1: Accountable Discipline 1:
Design shall consider new facility Accountable Discipline 2: Accountable Discipline 2:

impact such as process condition
AIPS-201203 and composition (e.g. pressure, End of BfD, FEED
8 No Process Not Applicable
temperature, water, salt) on tie-in as well DD
systems and connected
downstream existing facilities [DI]

Challenge/review the need for
having a surge relief valve (SRV). If
by design an SRV is required, the
design shall consider the ability of
an operator to respond adequate End of FEED as
14 AIPS-201205 and in time to the demands, e.g. No Process Not Applicable
well DD
have alarms available indicating the
relief valve has lifted (e.g. loss of N2
pressure). The alarm and response
time shall be documented in the
design basis [DI]

Facilities with the potential for
liquid hammering, such as steam
AIPS-201207 facilities, shall be designed to allow End of FEED as
21 Piping Not Applicable
for effective venting/draining of all well DD
piping and equipment prior to
commissioning and (re-)start [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

Process design review shall include
the impact and effects of inlet lines
AIPS-201208 with multiple feeds in both start-up End of FEED as
and operating scenarios, as well as well DD
and with these lines individually in
shutdown [DI]
Process design and facility reviews Accountable Discipline 2: Accountable Discipline 2:

shall evaluate pipe displacement
and movement of equipment due End of FEED as
25 AIPS-201208 to slug or liquid hammering effects, No Piping Not Applicable
well DD
with special attention to piping
supports and possible shearing off
of small bore connections [DI]

Design for fire and gas detection Accountable Discipline 2: Accountable Discipline 2:
End of FEED as Control &
29 AIPS-201209 systems at remote, (partially) No Not Applicable
well DD Automation
unmanned stations [DI]
For fouling service design for fail Accountable Discipline 2: Accountable Discipline 2:
safe conditions in case of faulty
AIPS-201209 reading of instrumentation and End of FEED as Control &
31 No Not Applicable
consider implementing means to well DD Automation
allow (continuous) flushing of
instrument lead lines [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

Provision shall be provided for Accountable Discipline 2: Accountable Discipline 2:
pressure testing of equipment at
the required (design) pressures. End of FEED as
35 AIPS-201210 System design shall allow for No Process Not Applicable
well DD
additional piping configuration to
facilitate this mandated pressure
testing [DI]
AIPS-201211 Above Ground GRE piping shall not End of FEED as Accountable Discipline 2: Accountable Discipline 2:
36 No Piping Not Applicable
be installed in fire zones [DI] well DD
Gaskets for equipment in acid

AIPS-201302 service shall comply with the End of FEED as
45 applicable design specifications and No well DD Piping Not Applicable
vendor recommendations [TI]

When designing Utility and non-HC
AIPS-201308 units review the need/requirement End of FEED as Accountable Discipline 2: Accountable Discipline 2:
54 No Technical Safety Not Applicable
for a Fire & Gas Detection System well DD
[DI]
The maximum discharge pressure Accountable Discipline 2: Accountable Discipline 2:

and trip setting of an Electrical
Submersible Pump (ESP) shall be
AIPS-201315 below the maximum allowable flow End of FEED as
line pressure and shall involve well DD
systems to relief pressure where
excursions above can be expected
[DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)
A steam boiler with a history of Accountable Discipline 2: Accountable Discipline 2:

End of BfD, FEED
89 AIPS-201406 having used hydrogen as a fuel No Process Not Applicable
as well DD
source shall not be re-used [DI]

Local control cabins in steam End of FEED as Accountable Discipline 2: Accountable Discipline 2:
90 AIPS-201406 injection facilities shall be located No Piping Not Applicable
well DD
to the side of boiler equipment [DI]

Facility layout, including temporary Accountable Discipline 2: Accountable Discipline 2:
AIPS-201406 (hired/leased) equipment shall End of FEED as
comply with applicable codes and well DD
standards [DI]
Header tie-in design and

AIPS-201407 configurations shall take flow End of FEED as
induced corrosion into well DD
consideration [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)
Remote facilities should be

identifiable in case of (3rd party)
report of incident at facility, and End of FEED as
102 AIPS-201409 where possible CCTV shall be Technical Safety Telecom
well DD
installed to provide ability to detect
larger leaks and spills at the site
[OI]
Design systems to prevent start-up Accountable Discipline 2: Accountable Discipline 2:

against high differential pressure.
Pressure equalization across (large) End of FEED as
108 AIPS-201411 valves shall always be done No Process Not Applicable
well DD
gradually to avoid damage to
piping/equipment due to hammer
effect [DI]

The design philosophy of a facility
shall ensure that all inlet wells and
flow lines to the main station/RMS
can be safely closed on process End of FEED as
153 AIPS-201502 upset or power failure, such that no No Process Not Applicable
well DD
pressure exceedance in the system
can develop. Positive identification
of no-flow should be available to
control room operator [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

The Plant Operating Manual and
the Process Safeguarding
Memorandum shall describe the
AIPS-201502 safeguarding at the interface and Operations in
154 No End of DD Process
should include the description of Design
the wells and how they will be shut
down, e.g. by PMR or other means
(including manual closure) [DI]
Remotely located relief valves shall Accountable Discipline 2: Accountable Discipline 2:

have indication to operations that
they have lifted (e.g. through a
AIPS-201502 pressure alarm). For an over- End of FEED as Control &
155 Not Applicable
pressure in an off plot location, well DD Automation
reset shall be local to ensure that a
reset is done after verification at
the location [DI]
Provide inlet pipe support outside

AIPS-201502 the bund wall to avoid having a End of FEED as
157 No Piping Civil
weak joint that could be vulnerable well DD
to washout [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

Remote relief pit shall be equipped End of FEED as Accountable Discipline 2: Accountable Discipline 2:
158 AIPS-201502 with level indicators to prevent No Process Not Applicable
well DD
overfill [DI]
Design Reviews for Modification

Projects shall include evaluation of
AIPS-201505 “dead-leg” potential, with the End of FEED as
objective to eliminate dead-legs well DD
where possible, and provide
mitigation when not possible [DI]

Facility Blowdown design of gas Accountable Discipline 2: Accountable Discipline 2:
End of FEED as
183 AIPS-201509 facilities shall comply with DEP No Process Not Applicable
well DD
80.45.10.12 (Blowdown) [DI]

When material selection specifies
AIPS-201510 CS with weld overlay, all sizes End of FEED as
smaller than 4” diameter shall be well DD
made of solid CRA material [DI]

Flare design, safe blower location Accountable Discipline 2: Accountable Discipline 2:
End of FEED as
244 AIPS-201605 and sterile area shall be part of No Process Technical Safety
well DD
facility design review [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

Ensure piping analysis, near
AIPS-201704 rotating equipment, shall include End of FEED as
vibration as well as stress analysis well DD
[DI]
Accountable Discipline 1: Coplete hook-up is Accountable Discipline 1:

demolised and there will not be any dead legs
left. Accountable Discipline 2:
Accountable Discipline 2:
Project teams shall ensure that

AIPS-201720 decommissioning scope does not End of FEED as
353 Yes Process Not Applicable
leave dead legs behind in the well DD
process system [DI]
Effluent treatment sampling system

shall be designed in such a way that End of FEED as
363 AIPS-201724 release and loss of product to the No Process Not Applicable
well DD
environment does not occur when
taking samples [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)

Verify during design whether an Accountable Discipline 2: Accountable Discipline 2:
AIPS-201729 insulation gasket is required, e.g. End of FEED as
when dissimilar materials are used well DD
[DI]

The use of a non-standard gasket End of FEED as Accountable Discipline 2: Accountable Discipline 2:
378 AIPS-201729 requires an MOC and needs to be No Piping Not Applicable
well DD
approved by appropriate CFDH [DI]

Project ID:
Project Name:
Project Stage:
Date:
(Yes or No)
The learnings from Learning from Incidents (LFI) are embedded in the project are endorsed by the following persons as applicable to confirm that they that are suitable, appropriate and robust to manage that the reoccurrence of the potential incidents are
Civil Eng TA2 (Name & Ref ID): Signature: Date:
Control & Automation Eng TA2 (Name & Ref ID): Signature: Date:
Electrical Eng TA2 (Name & Ref ID): Signature: Date:
Materials & Corrosion Eng TA2 (Name & Ref ID): Signature: Date:
Pipelines Eng TA2 (Name & Ref ID): Signature: Date:
Piping Eng TA2 (Name & Ref ID): Signature: Date:
Process Eng TA2 (Name & Ref ID): Signature: Date:
Project Management Eng TA2 (Name & Ref ID): Signature: Date:
Design
Integrity
& Quality Eng TA2 (Name & Ref ID): Signature: Date:
Technical
Integrity
Rotating Eng TA2 (Name & Ref ID): Signature: Date:
Static Eng TA2 (Name & Ref ID): Signature: Date:
Technical Safety Eng TA2 (Name & Ref ID): Signature: Date:
Telecom Eng TA2 (Name & Ref ID): Signature: Date:

Design
Integrity
Project ID:
& Name:
Project
Technical
Project Stage:
Integrity No. & Rev.No:
Document
Date:
(Yes or No)
Operations in Design TA2 (Name & Ref ID): Signature: Date:
M&I in Design TA2 (Name & Ref ID): Signature: Date:
Commissioning Eng TA2 (Name & Ref ID): Signature: Date:
Construction TA2 (Name & Ref ID): Signature: Date:

from Incidents (LFI) Tool
M
Remarks &
I
i
n
D
e
s
i
g
n
The same learning is also

appeared for the Incident
Reference ID: AIPS-201511

Remarks
The startup of the process unit

shall be discussed under the
"Start-up" guide word during
HAZOP and the supports shall be
designed for the inputs provided
in the Line List.
The same learning is also

appeared for the Incident
Reference ID: AIPS-201411
failsafe Design is always

implemented and followed,
instrument flushing by means of
standard mono-flanged
arrangement (SDB & DDB)

Remarks

Remarks
Process: To review the line

velocities as part of line sizing
and to be captutred in line list as
per codes and standards.
Highlight if any higher velocities
cases and to be captured
accordingly in the design.
Piping: To update piping size

based on Process input.

Remarks
Facility identification is
mandatory requirement. This has
to be part of the Safety Sign and
CCTV to be assessment to be
done case to case basis.
This learning is applicable to trip

of wells by PMR based on the
inputs from Ptrocess & C&A to
demonstrate this learning in
projects.
Process Inputs to C&A: The PMR

trip details to be reflected in PEFS
C&A Inputs: The FCS & IPS logic

details to be provided to
Electrical indicating the scheme
how to built the logic to address
this learning.

Remarks
The scope of Hazop to remove

the HIPPS lekage RV only and
existing wells hook-ups are being
replaced by DSS materail.

Remarks
Key Learning shall be considered

to mention that drain/vent plug
threaded portion shall also be
provided with weld overlay when
specified weld overlay for the
valve.
Remark: The flare design only

considers normal liquid carry
over and hence not designed for
bulk liquid.

Remarks
It is covered in DEP-31.38.11.01
and GU-706 for Stress analysis
If the MOC of the dead leg which

will be created due to demolition
is CRA than there is no issue.
However if the MOC which will
be created due to demolition is
Carbon Steel than the same
needs to be discussed with Asset
to whether the demoliton of the
dead leg shall also be part of the
project scope or will be taken by
the Asset separately.

Remarks

Remarks
able to confirm that they that are suitable, appropriate and robust to manage that the reoccurrence of the potential incidents are eliminated.
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:
Date:

Remarks
Date:
Date:
Date:
Date:

LFI Tool - PD-HX-REP-003 Rev.01

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PDO FEED OFFICE

Learnings from Incidents (LFI) Tool

Document No: FEED-HX-REP-003

01 6/17/2019 Issued for Approved UEFH3/SE UEFH/MD UEFH/MD

Rev. Date Description Originator Checker Approver

Format No:FEED-QM-FOM-023, Rev.06

Template No: FEED-HX-REP-003 Rev.01 Page 2 of 26

4. Deviation from Learnings:

Template No: FEED-HX-REP-003 Rev.01 Page 3 of 26

Template No: FEED-HX-REP-003 Rev.01 Page 4 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

Design shall consider new facility Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Template No: FEED-HX-REP-003 Rev.01 Page 5 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Process design and facility reviews Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 1: Accountable Discipline 1:

Template No: FEED-HX-REP-003 Rev.01 Page 6 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Gaskets for equipment in acid

Accountable Discipline 1: Accountable Discipline 1:

The maximum discharge pressure Accountable Discipline 2: Accountable Discipline 2:

Template No: FEED-HX-REP-003 Rev.01 Page 7 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

A steam boiler with a history of Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Header tie-in design and

Template No: FEED-HX-REP-003 Rev.01 Page 8 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Remote facilities should be

Accountable Discipline 1: Accountable Discipline 1:

Design systems to prevent start-up Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Template No: FEED-HX-REP-003 Rev.01 Page 9 of 26

Learning from Incidents (LFI) Tool

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Remotely located relief valves shall Accountable Discipline 2: Accountable Discipline 2:

Accountable Discipline 1: Accountable Discipline 1:

Accountable Discipline 2: Accountable Discipline 2:

Provide inlet pipe support outside

Template No: FEED-HX-REP-003 Rev.01 Page 10 of 26

Learning from Incidents (LFI) Tool