HAZOP Example

HAZOP Example
Here is an example of how a HAZOP can be used by an expert team to assess the procedure involved in
chemical production:

Setting: Chemical Mixing Plant

Objective: To produce a batch of 10% concentration HCl (Hydrochloric acid)
Steps:
1. Reverse Osmosis (RO) water is added to the batch mixer via centrifugal pump
2. Additives are mixed with the RO water
3. A 33% solution of HCl is added to the mixture of RO water and additives, resulting in 10%
concentration HCl

Guide word/Scenario: No RO water added.

Possible cause(s): Centrifugal pump loses priming or valve closed totally.
Consequence(s): Solution will be highly concentrated.
Safeguard(s): Proper monitoring of the centrifugal pump (hydraulic pressure).
Comments: Hydraulic pressure gauge should be reviewed and maintained on a regular basis.
Recommendation(s): Review and do maintenance work on the hydraulic pressure gauge of the centrifugal
pump.

HAZOP Guide Words

After identifying the objective and steps involved in the procedure, the team will then explore different
scenarios where the procedure could deviate from its intended function.

A HAZOP study encourages the use of “guide words” to help explore all potential deviations. Here is an
example of how the team could use common guide words to explore deviations involving the input and
mixture of RO water:

 No or not (Design intent negated completely) – No RO water added

 More (Quantitative increase) – RO water added is more than intended
 Less (Quantitative decrease) – RO water added is less than intended
 As well as (Qualitative modification/increase) – RO water mixed with UV water is added
 Part of (Qualitative modification/decrease) – Tap water is added instead of RO water
 Reverse (Logical opposite of design intent) – RO water is omitted from the mixture
 Other than (Complete substitution) – UF water is used instead of RO water
 Early (Relative to the clock time) – RO water is added too early
 Late (Relative to the clock time) – RO water is added too late
 Before (Relating to order or sequence) – RO water is added before the additives and 33% HCl are
ready
 After (Relating to order or sequence) – RO water is added after the additives and 33% HCl

In the first scenario where “No RO water is added” the team will deliberate and identify the possible causes,
consequences, safeguards and ultimately provide a recommendation.

HAZOP Software
Use iAuditor by SafetyCulture to streamline data gathering and reporting. With iAuditor, you can:
 Complete and document your HAZOP study using your smartphone/ tablet while on-site with your
expert team without returning to the office.
 Take unlimited photo evidence and annotations of design systems and deviations.
 Use voice dictation to save time and record detailed notes.
 Securely save all your reports in the cloud and easily access them online.

To help you get started, we have created a free HAZOP template that you can download and customize for
your purpose.

Featured HAZOP Template

HAZOP Template
A HAZOP template is used to identify risks in a plant design, procedure, or operation. Use this template to
conduct a HAZOP study where you can:

 list multiple scenarios for a variety of deviations to study

 identify critical safety and improvement points for your design, system or process
 capture photo evidence for risk hazards and opportunities for improvement
 provide current safeguards that prevent risk and operational failure
 assign actions and notify personnel in real-time