HAZOP template

Before beginning, gather your process flow diagrams, P&IDs, operating procedures, and previous incident reports. Assemble a cross-functional team with operational, engineering, and safety expertise. Also identify the specific process nodes or sections you’ll analyze, as breaking complex systems into manageable segments makes the HAZOP process more effective and thorough.

The duration depends on your process complexity, but plan for 1-3 days per major process node. Don’t rush—thorough analysis prevents incidents. Allow adequate time for team discussion of each deviation scenario, documentation of findings, and development of recommendations. Remember that investing time upfront in hazard identification saves significantly more time that would be lost addressing incidents later.

Evaluate each identified hazard based on both severity of potential consequences and likelihood of occurrence. Focus first on scenarios with severe consequences and inadequate safeguards. Document your risk ranking criteria within the template to ensure consistency. Then develop an implementation timeline that addresses the highest-risk items first while maintaining momentum on all necessary safety improvements.

For each identified deviation, list existing safeguards with specific details—don’t just write “alarm” but specify “high-pressure alarm PAH-101 set at 95 psig.” Distinguish between preventive safeguards (that stop the deviation) and mitigative ones (that reduce consequences). Be honest about safeguard limitations and note where additional protection layers might be needed for critical scenarios.