A HAZOP (Hazard and Operability) study is a structured risk assessment method used to identify process hazards, operational issues, and safety deviations in industrial systems. Widely used across chemical, oil & gas, pharmaceutical, and manufacturing industries, HAZOP helps organizations improve process safety, ensure compliance, and reduce operational risks before incidents occur.
Aura Safety provides HAZOP study and facilitation services for new projects, existing plants, and process modifications across India. Our consultants help clients define the study scope, prepare process nodes, conduct multidisciplinary workshops, and document deviations, causes, consequences, safeguards, and recommended actions.
Whether you are preparing for commissioning, reviewing a process modification or reassessing an operating facility, Aura Safety can help you conduct a structured HAZOP study and produce an actionable study report.
Share your project stage, facility location, approximate number of P&IDs and preferred schedule.
A Hazard and Operability Study, commonly called a HAZOP study, is a systematic examination of a planned or existing process. Its purpose is to identify hazards, operating difficulties, and deviations that could affect people, equipment, the environment, product quality, or continuity of operations.
The process is divided into manageable sections called nodes. A multidisciplinary team applies guide words such as No, More, Less, Reverse, Other Than, As Well As,” and “Part Of” to relevant parameters such as flow, pressure, temperature, level, and composition.
For each credible deviation, the HAZOP team examines:
IEC 61882 provides international guidance on HAZOP principles, preparation, examination, documentation and follow-up.
A HAZOP study asks a structured series of “what could go wrong?” questions about each part of an industrial process. It helps the study team identify unsafe deviations before they result in an incident, equipment failure, or operating disruption.
A design-stage HAZOP identifies hazards and operability issues while changes can still be incorporated into the engineering design.
A pre-startup study helps confirm that critical process deviations, safeguards and operating requirements have been considered before hazardous materials are introduced.
Changes to equipment, process conditions, controls, chemicals, utilities or operating procedures can introduce new hazards. A HAZOP may form part of the management-of-change process.
An operating facility may require a HAZOP to review an existing process, address incomplete historical documentation, or evaluate current safeguards.
An earlier study may need to be reassessed after significant operational experience, accumulated modifications, incidents or changes in process knowledge.
Aura Safety provides structured HAZOP study services from initial preparation through workshop facilitation, reporting and recommendation follow-up.
Our HAZOP consulting services can include:
The final scope is determined according to the process, project stage, available documentation and required deliverables.
Guide words are applied to relevant process parameters to help the HAZOP team identify credible deviations from the intended process design.
Guide word | General meaning | Example deviation |
No/None | The intended function does not occur | No flow |
More | Quantitative increase | More pressure |
Less | Quantitative decrease | Less temperature |
Reverse | Opposite direction or sequence | Reverse flow |
Other Than | Complete substitution | Other-than composition |
As Well As | Additional material or activity | Contamination in feed |
Part Of | Only part of the intention occurs | Incomplete reaction |
Only guide-word and parameter combinations relevant to the node should be examined. The team should also consider process-specific prompts where appropriate.
The following simplified example shows how a process deviation may be recorded during a HAZOP workshop.
Node | Feed line to process vessel |
Design intent | Transfer feed at the specified flow and pressure |
Deviation | No flow |
Possible causes | Pump failure, closed valve or blocked line |
Possible consequences | Process interruption, abnormal vessel condition or upstream pressure increase |
Existing safeguards | Flow indication and low-flow alarm |
Recommendation | Review whether an automatic response or additional safeguard is required |
Action owner | Assigned by the client team |
Target date | Agreed during close-out |
Important: This example is illustrative and is not a substitute for a project-specific HAZOP study.
The following checklist can help a project team prepare for a structured HAZOP study.
A checklist provides preparation and documentation control; it does not replace the guide-word-driven multidisciplinary examination.
The exact requirements depend on the process and project stage, but clients should normally provide:
Poor-quality or outdated documentation can reduce workshop efficiency. Document readiness should therefore be checked before confirming the study schedule.
A HAZOP is conducted by a multidisciplinary team. Depending on the project, participants may include:
Team member | Typical responsibility |
HAZOP facilitator | Leads the structured examination and maintains the methodology |
Scribe | Records deviations, causes, consequences, safeguards and actions |
Process engineer | Explains process design and operating parameters |
Operations representative | Provides practical operating knowledge |
Instrumentation or control engineer | Reviews alarms, interlocks and control functions |
Mechanical or maintenance representative | Provides equipment and reliability knowledge |
Process-safety specialist | Supports hazard and risk evaluation |
Project or design representative | Clarifies design decisions and interfaces |
The client should appoint participants with sufficient authority and technical knowledge to contribute meaningfully.
Subject to the agreed scope, the final HAZOP study deliverables may include:
The report structure, submission format, and recommendation-tracking requirements should be agreed upon during project scoping.
HAZOP studies are particularly relevant to facilities involving hazardous substances, complex process operations, stored energy, critical controls or significant operating consequences.
Aura Safety provides HAZOP study support for process and industrial facilities across India, including:
Method | Primary purpose | Typical application |
HAZID | Broad identification of major hazards | Concept and early design |
HAZOP | Detailed examination of process deviations | Detailed design, process modifications and operating plants |
LOPA | Evaluation of protection-layer adequacy | Higher-risk scenarios identified through a PHA |
QRA | Quantification of event frequency and consequences | Major accident and land-use risk decisions |
A project may require more than one method. The correct study depends on project maturity, available information, process complexity, and the decisions that need to be supported.
Aura Safety supports HAZOP engagements from initial scoping and document review through workshop facilitation, reporting, and action tracking.
Clients receive:
Before the project begins, the proposed scope should clearly identify the required inputs, workshop approach, schedule, responsibilities, and final deliverables.
Share your project stage, facility location, process type, approximate number of P&IDs and preferred schedule. Our team will review your requirement and help define an appropriate HAZOP scope.
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Discuss your process, project stage, available documentation and required schedule before finalizing the study scope.
It is a team-based review used to identify and control potential hazards in a process.
It uses guide words and a systematic approach rather than general checklists.
During design, plant changes, or regular safety reviews.
Experts from process, operation, maintenance, instrumentation, and safety.
A report listing deviations, causes, safeguards, and actions.
Unclear scope, incomplete data, and low team involvement.
No, More, Less, Reverse, and Other Than.
The most common problems are "No Flow" (a blocked pipe), "More Pressure" (risk of bursting), and "Reverse Flow" (liquid going the wrong way).
HAZOP is much more detailed. It looks at the "How" and "Why" of every single moving part, whereas other methods just look at general risks.
It is the standard because it is a system. It ensures that no part of the plant is skipped. It is trusted by governments and insurance companies worldwide.
The Oil and Gas, Chemical, Pharmaceutical, and Manufacturing industries use HAZOP the most to prevent big accidents and protect their workers.
