At a glance
- Free Excel download (XLSX), no sign-up, free to adapt.
- Includes instructions, a study header, a 21-column HAZOP worksheet, a guide word reference and an example 5 × 5 risk matrix.
- Risk is ranked without and with safeguards, so the unmitigated risk stays visible.
- The example rows cover a node “methanol feed via pump to reactor” with the guide words NO, MORE and OTHER THAN.
Download the HAZOP template (Excel)
Instructions, study header, HAZOP worksheet with drop-downs, guide words and an example risk matrix.
XLSX · 5 sheets · approx. 30 KB
What belongs in a HAZOP worksheet?
The HAZOP worksheet records, node by node, which deviations the team examined, how it ranked them and which actions follow. The template’s columns follow the flow of a HAZOP study:
| Column | Content | Tip |
|---|---|---|
| Node | A defined section of the P&ID | Choose nodes so that a clear design intent can be stated. |
| Design intent | What the node is meant to do, with design values | Use numbers: substance, flow, pressure, temperature. |
| Parameter and guide word | The combination that creates the deviation, e.g. flow + NO | Only pursue combinations that make physical sense. |
| Cause | What can trigger the deviation | One cause per row keeps ranking and follow-up unambiguous. |
| Consequence | What happens without taking safeguards into account | Think through to the worst credible outcome. |
| Risk without safeguards | Severity S, likelihood L, risk number R | Use your company’s risk matrix. |
| Existing safeguards | Engineering and administrative barriers | Only credit safeguards that are effective and independent. |
| Risk with safeguards | Residual risk | Shows whether further action is needed. |
| Recommendation, owner, due date, status | Action tracking | Every recommendation needs an owner and a due date. |
Which guide words fit which parameters is covered in our HAZOP guide words reference. The template offers the same guide words as a drop-down list.
How to fill in the template
- Complete the study header: facility, scope, documents with P&ID number and revision, team and session dates, so it stays clear which design basis the study used.
- Define the nodes: split the P&ID into sections with a clear design intent, e.g. “transfer methanol at 5 m³/h, 20 °C and 4 barg to the reactor”.
- Derive deviations: combine the relevant parameters of each node with the guide words. Not every combination is meaningful – the team decides which ones to pursue.
- Record causes and consequences: one cause per row, and the consequences as they would unfold without safeguards.
- Rank the risk: enter severity and likelihood before and after safeguards. The template calculates R = S × L and colours it according to the example matrix.
- Track recommendations: record actions with owner, due date and status and follow them up until they are implemented and verified.
Worked example: one node, three guide words
The template’s example rows examine the node “methanol feed from storage tank T-101 via pump P-101 to reactor R-201”. Three extracts:
| Deviation | Cause | Consequence without safeguards | Existing safeguard | Recommendation |
|---|---|---|---|---|
| NO flow | Manual valve HV-103 left closed after maintenance | Pump runs against a closed valve, the mechanical seal is damaged, methanol can be released | None | Minimum-flow line or low-flow pump trip; add the valve line-up to the restart checklist |
| MORE pressure | Pump shut-off head above the line design pressure | Flange leaks, release, fire and explosion hazard | Pressure safety valve PSV-104 | Verify PSV-104 for the closed-valve case |
| OTHER THAN (composition) | Wrong product unloaded into the tank | Unwanted reaction in the reactor | Sampling and laboratory release | Label or key the unloading connections by product |
The rows are deliberately simple and do not replace an assessment of your plant. They show how specific causes and consequences should be written so the team can still follow them months later.
Common mistakes in HAZOP worksheets
- Several causes in one row: the ranking becomes vague because the causes have different likelihoods.
- Safeguards hidden in the consequence: wording like “relief valve opens, no consequence” makes the unmitigated risk disappear. The consequence describes what happens without safeguards.
- Vague design intent: without design values, deviations such as MORE or LESS cannot be derived cleanly.
- Nodes that are too large: the discussion loses focus and causes get missed.
- Recommendations without owner or due date: they are forgotten after the session.
- No link to the drawing revision: if the study does not record which P&ID revision it used, it is hard to verify after changes.
Where spreadsheets reach their limits
For small studies with a handful of nodes, a spreadsheet is perfectly adequate. As studies grow, spreadsheets struggle with several editors, P&ID revisions, action tracking over months, and the question of who changed which ranking and when.
HAIZOP keeps the HAZOP worksheet as structured data: from the P&ID, plant profile and substance data it prepares reviewable drafts of deviations, causes, consequences and safeguards. Your team reviews, corrects and approves; an audit trail records every change. See the platform overview and our guide to AI in HAZOP studies.
Frequently asked questions
Is the HAZOP template free?
Yes. The Excel template can be downloaded without registration and may be used and adapted for your own HAZOP studies.
Which risk matrix should I use?
The template includes an example 5 × 5 matrix. For the actual ranking, use the risk matrix defined by your company, with its levels and tolerability limits.
Does the template follow IEC 61882?
The columns follow the usual HAZOP recording practice described in IEC 61882: node, design intent, parameter, guide word, deviation, causes, consequences, safeguards and actions. How you rank risk is defined by your own procedures.
Does a template replace an experienced HAZOP facilitator?
No. The template structures the documentation. The quality of the study depends on the multidisciplinary team and an experienced facilitator.
Is there a German version?
Yes. The German version is called HAZOP-Vorlage and is available at haizop.de/hazop-vorlage.