HAZOP analysis template

Break your process into logical sections where parameters (like flow, temperature, pressure) remain consistent. Focus on areas with hazardous materials, complex operations, or previous incidents. Include interfaces between systems and critical control points. Your P&ID diagrams will guide this breakdown, typically resulting in 10-20 nodes for a medium-sized process.

Assemble a diverse team with complementary expertise: an experienced facilitator, process engineers familiar with the design, operations personnel who work with the system daily, safety specialists, and maintenance staff. Include 5-8 members total. For specialized processes, include subject matter experts like chemical engineers or automation specialists. The diversity of perspectives is key to identifying all potential hazards.

Use the risk assessment section of the template to assign probability and severity ratings to each identified hazard. Focus first on items with high risk ratings (combinations of high probability and severe consequences). Consider implementation difficulty and cost as secondary factors. Document your prioritization rationale to demonstrate due diligence and ensure the most critical safety improvements happen first.

Prepare current process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), operating procedures, material safety data sheets, and equipment specifications. Have previous incident reports and maintenance records available. This template includes fields to verify diagram attachment. Good preparation enables your team to focus on analysis rather than searching for basic information during the session.