Process Hazard Analysis (HAZOP) Worksheet
A process hazard analysis asks what could go wrong with a process, why, and what already protects people. This worksheet follows the HAZOP pattern of node, parameter and guide word so a team can record each deviation, its risk and follow-up in one editable table.
| Node | Parameter | Guide word | Cause | Consequence | Severity (1-5) | Likelihood (1-5) | Risk score | Existing safeguards | Recommended action | Owner | Due date | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
12 | ||||||||||||
6 | ||||||||||||
10 | ||||||||||||
9 | ||||||||||||
10 |
Scores use severity 1 to 5 and likelihood 1 to 5; define the scale and the action threshold in your own risk matrix (for example 10 or above needs action). This worksheet supports a PHA team but does not replace a facilitated study or your legal obligations.
Track hazard actions in your ERP
Optional: a short review of linking PHA recommendations and MOC records to maintenance work orders.
Optional. The tool and every export work without this. No spam.
How to use the worksheet
Divide the process into nodes such as a reactor feed line, a jacket or a storage tank. For each node, apply a process parameter (flow, pressure, temperature, level, composition) with guide words (no, more, less, reverse, as well as, part of, other than) to describe a deviation. Record the cause, the consequence, existing safeguards, a severity and likelihood score, and an action with an owner and date. The risk score is computed per row, and the summary shows the highest score so you can sort actions by priority.
- Review one node at a time with operations, maintenance and engineering present.
- Score the consequence with the safeguards you have actually verified.
- Assign every action an owner and date, then track closure.
The method and its context
HAZOP is a structured team technique, commonly used to satisfy process hazard analysis requirements such as OSHA 29 CFR 1910.119 in the US for covered processes, and similar rules elsewhere. Other accepted methods include what-if, checklists, FMEA and fault tree analysis. A simple severity times likelihood score is a prioritisation aid, not a quantified risk assessment, and layers of protection analysis is often used when a scenario needs more rigor.
Common mistakes
Teams often list causes that are really consequences, claim safeguards that are procedures nobody follows, or score likelihood assuming the alarm always works. Others skip startup, shutdown and maintenance modes, treat the study as a one-time document, or leave actions open without owners. Re-validate the study on the schedule your regulations require and after any significant change; link management of change records to the affected nodes.
- Do not credit an alarm that is routinely ignored.
- Include non-routine modes.
- Close actions before the next revalidation.
Frequently Asked Questions
What are the HAZOP guide words?
The usual set is no or none, more, less, reverse, as well as, part of and other than. Combined with a parameter such as flow or temperature, they generate deviations like more flow or less temperature that the team then examines for causes and consequences.
Is this worksheet enough for OSHA PSM compliance?
It is a recording tool. A compliant PHA needs a qualified team, an appropriate methodology, documented findings, resolution of recommendations and periodic revalidation. Use the worksheet to capture the work, and confirm obligations with your safety professionals.
How is the risk score calculated?
Each row multiplies severity by likelihood, both on a 1 to 5 scale, giving a score from 1 to 25. Set your own threshold for required action in your risk matrix; the numbers here are an example you should align with company policy.
Can I export the worksheet?
Yes. Use the export buttons for Excel, PDF or CSV. Many teams export to Excel to sort by risk score and assign actions, then keep the file with the study records.
Netray can help connect hazard study actions with ERP maintenance work orders and change records, so recommendations are tracked to closure in the system you already use.
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