HAZOP Register
Template (Excel)
Free HAZOP action register template in OISD 118-compliant format. Track actions, map to P&ID nodes, and monitor closure. Or let Pathnovo auto-generate registers from your HAZOP PDFs.
Template Fields
Node Reference
P&ID Reference
Parameter
Guide Word
Deviation
Cause
Consequence
Frequency Rating
Severity Rating
Likelihood Rating
Risk Priority
Existing Safeguards
Recommendation
Action Item
Action Type
Responsible Party
Due Date
Status
Closure Evidence Reference
OISD 118 Clause Reference
SIL Classification (if applicable)
HAZOP Node Walk-Through Examples
Three example HAZOP node entries showing how the template captures parameter, guide word, deviation, cause, consequence, safeguards, and recommendation per IEC 61882 methodology. Examples drawn from typical Indian PSU refinery and petrochemical scope.
Node 1: Crude column overhead piping
Parameter
Flow
Guide word
No / Less
Deviation
Loss of overhead vapour flow to the air-cooled condenser bank
Cause
Closure of motorised control valve due to control system failure; upstream pump trip; high differential pressure across condenser
Consequence
Overpressure of crude column above design pressure; potential PRV lifting; vapour release at relief header; fire / explosion if ignition source present
Existing safeguards
PRV on column top (set at 1.05x design pressure), high-pressure shutdown trip via SIS, flare header connection to safely route relief, operator high-pressure alarm at DCS
Recommendation
Verify PRV setpoint per OISD 118 sizing per current load case; confirm SIS trip logic per IEC 61511 SIL classification
Node 2: Hydrocracker reactor feed
Parameter
Temperature
Guide word
More
Deviation
Excessive reactor inlet temperature above design
Cause
Fired heater BMS failure; fuel gas pressure surge; loss of cooling on quench injection
Consequence
Runaway exothermic reaction in catalyst bed; bed temperature excursion; potential catalyst sintering or vessel overpressure; uncontrolled reaction propagation
Existing safeguards
Bed temperature high-high trip via SIS, emergency depressurisation valve activated by SIS, redundant temperature sensors for voting logic, fired heater BMS independent of process control system
Recommendation
Confirm SIS architecture meets SIL 3 per LOPA worksheet; verify proof test interval per IEC 61511; update fired heater BMS per OISD 150 if applicable
Node 3: LPG storage vessel
Parameter
Level
Guide word
More
Deviation
High liquid level approaching maximum operating level
Cause
Failure of high-level alarm response by operator; failure of high-high level shutdown valve; uncontrolled feed from upstream
Consequence
Liquid carryover into vapour line; potential overpressure of downstream vapour piping; flame / explosion hazard if release to atmosphere
Existing safeguards
High-level alarm at DCS, high-high level shutdown trip via SIS, mechanical level gauge for independent verification, blowdown to flare header for emergency depressurisation
Recommendation
Verify high-high level SIS architecture per LOPA worksheet; confirm CCOE Form XIV emergency response plan covers scenario; update OISD 118 inter-distance compliance if vessel capacity exceeds 1,000 m3
OISD 118 Alignment Notes
OISD 118 (Layout for Oil and Gas Installations) governs HAZOP study requirements for Indian petroleum installations under MoPNG jurisdiction. The template column set aligns with OISD 118 audit-pack requirements and PNGRB inspection expectations. Key alignment points below.
Chapter 3 inter-distance compliance link
Every HAZOP recommendation that affects equipment placement, vessel capacity, or hazardous area extent must update the OISD 118 Chapter 3 inter-distance compliance table. The template OISD 118 Clause Reference column ties each action to the relevant Chapter 3 row (Class A petroleum tank-to-tank, tank-to-boundary, tank-to-public-road, equipment-to-boundary). Pathnovo's compliance bundle auto-validates the inter-distance impact when P&ID and plot plan revisions arrive. See the OISD 118 compliance page for the automated workflow.
MoPNG / PNGRB audit-ready format
MoPNG and PNGRB audits require structured HAZOP register output covering scope, methodology, findings, recommendations, and closure status. The template column set matches MoPNG audit-pack expectations: node-by-node detail, IEC 61882 methodology compliance, risk rating per OISD-aligned matrix, recommendation with closure timeline, evidence document link. Audit-day desk review drops 60-80% when registers are pre-structured.
Superseded-node detection
The most common HAZOP register failure mode: actions close on superseded P&ID nodes (tags renamed, equipment replaced, lines re-routed during construction). When the auditor walks the plant, recommendations point at nothing on the current plant. The template P&ID Reference column captures the current revision; Pathnovo's HAZOP register extraction product flags superseded nodes automatically across multi-year HAZOP histories.
SIS / SIL traceability
HAZOP recommendations triggering Safety Instrumented Functions (SIF) require formal SIL classification per IEC 61511 and downstream LOPA quantification. The template SIL Classification column ties each SIS-relevant recommendation to its SIL level (typically SIL 2 or SIL 3 in refinery and petrochemical scope). See the SIL standard reference for the full classification framework.
Cloud-Based HAZOP Documentation Tools
Where to find cloud-based tools for HAZOP documentation depends on which part of the workflow you need help with: live workshop facilitation, enterprise PHA register management, or extracting and maintaining the post-workshop register from completed study PDFs. Honest map of the three categories below.
SALUS HAZOP AI
Live workshop facilitation (cloud)Documentation fit
Strong for the live session: real-time guide-word prompts, parameter coverage tracking, action capture during the workshop. Weak for post-workshop documentation: the completed HAZOP study still exits as a PDF and the action register has to be maintained manually downstream.
Best for
Active HAZOP facilitators running studies week-to-week who want a cloud-native replacement for paper / spreadsheet workshop tooling.
Kairos Technology
Live workshop facilitation (cloud)Documentation fit
Similar profile to SALUS, focused on facilitation. Cloud workspace for the team during the study, with action items exported as Excel or PDF at study close. Does not extract from prior PDF HAZOP studies and does not maintain the register across multi-year closure cycles.
Best for
Owner-operators with internal HAZOP teams running 20+ studies a year who want a single facilitation workspace.
Sphera Process Hazard Analysis (PHA-Pro)
Enterprise PHA register + documentation (cloud and on-prem)Documentation fit
Strongest at the enterprise documentation end: structured PHA register, IEC 61882 / 61511 alignment, multi-study consolidation, closure workflow with sign-off matrix. Used by tier-1 owner-operators (Shell, BP scale). Enterprise pricing and 6-12 month implementation typical.
Best for
Tier-1 owner-operators with multi-asset PHA programmes and budget for enterprise software.
Pathnovo (HAZOP register extraction)
Document extraction + register automation (cloud)Documentation fit
Cloud-based extraction layer for completed HAZOP study PDFs (800 to 3,000 pages typical). Outputs an audit-ready register mapped to current P&ID revisions, with superseded-node detection, OISD 118 clause cross-references, and SIL classification on SIS-relevant actions. Fills the gap SALUS / Kairos / Sphera don't cover: turning the post-workshop PDF into a queryable, maintained register.
Best for
EPC contractors and mid-size operators with HAZOP studies trapped in PDF that need OISD 118 / IEC 61882 audit-ready format in 48 to 96 hours, without an enterprise software programme.
V2 Template Coming Soon
The v2 HAZOP register template (in development) extends the current v1 template with pre-populated regulatory cross-references and embedded methodology worksheets. The downloadable v2 is available to Pathnovo customers and prospects on request via the contact form. Preview the v2 feature set below.
Pre-populated OISD 118 Chapter 3 inter-distance lookup table reference column for quick layout impact checks
Pre-populated PESO Form XIV / XV cross-reference column for pressure equipment safety device tracking
Pre-populated IBR Form IV register link column for pressure equipment HAZOP recommendation traceability
Pre-populated CCOE licence reference column for licence-scoped equipment HAZOP actions
Embedded LOPA worksheet template for semi-quantitative risk quantification per CCPS methodology
Embedded SIL classification matrix per IEC 61511 with proof test interval tracking
Embedded Cause & Effect (C&E) matrix template for SIS verification per C&E matrix vs P&ID verification
Closure verification workflow with sign-off matrix (engineering, safety, operations, maintenance)
Auto-generated audit-day desk review summary sheet for MoPNG / PNGRB / OISD audit preparation
Frequently Asked Questions
What is a HAZOP action register?
A HAZOP action register tracks every recommendation and action item from a HAZOP (Hazard and Operability) study. For each identified deviation, the register records the node, parameter, guide word, cause, consequence, existing safeguards, risk rating, recommendation, action item, owner, due date, status, and closure evidence. OISD 118 requires maintained HAZOP registers for all petroleum installations in India; IEC 61882 provides the international equivalent.
Can Pathnovo auto-generate HAZOP registers from PDF studies?
Yes. Pathnovo extracts HAZOP actions from completed PDF studies (800-3,000 pages typical for refinery / petrochemical units) into structured registers in 48-96 hours. Actions are mapped to current P&ID revision nodes (superseded nodes flagged), classified by OISD-aligned priority, and formatted for OISD 118 / IEC 61882 / MoPNG audit submission. See the HAZOP register extraction workflow for the full pipeline.
How is this different from SALUS HAZOP AI or Kairos Technology?
SALUS and Kairos are HAZOP facilitation tools for live workshops; they record actions during the study. They do not extract data from completed study PDFs. Pathnovo starts where facilitation tools leave off: the post-workshop document that historically sits in Excel becomes a queryable, audit-ready register. See the SALUS HAZOP alternative for the full comparison.
What columns are required for OISD 118 compliance?
OISD 118 expects: node reference, P&ID reference with current revision, parameter and guide word (HAZOP methodology), deviation, cause, consequence, existing safeguards, risk rating (OISD-aligned matrix), recommendation, action item with owner and due date, closure evidence, status tracking through to verified closure. The template provided covers all required columns plus optional SIL classification for SIS trip loops.
Does the template work for IEC 61882 HAZOP studies (international)?
Yes. The column set maps to IEC 61882 (HAZOP Application Guide) methodology: process node, parameter, guide word, deviation, cause, consequence, safeguards, recommendation. International operators (Shell, BP, Chevron, TotalEnergies, Equinor) typically use IEC 61882 directly; Indian O&G operators under MoPNG jurisdiction add OISD 118 specifics. Template supports both with optional OISD 118 clause reference column.
How do I track HAZOP action closure?
The template Status column supports: Open, In Progress, Under Verification, Closed-Implemented, Closed-Accepted-Risk, Superseded. Closure Evidence Reference column links to the document proving implementation (MoC record, SAP PM work order number, training attendance sheet, engineering change notice, verification report). For plants running SAP QM or TrackWise, the column linkage makes integration straightforward.
What if my HAZOP P&ID references are out of date?
This is the single most common HAZOP register problem: actions close on superseded P&ID nodes (tags renamed, equipment replaced, lines re-routed), meaning trip loops and recommendations point at nothing on the current plant. Pathnovo's automated HAZOP extraction service maps every action to the current P&ID revision with superseded-node detection. Manual tracking cannot catch this at scale. See the OISD 118 compliance workflow for full OISD 118 automation.
Where to find cloud-based tools for HAZOP documentation?
Cloud-based HAZOP tooling falls into three categories, and they solve different parts of the workflow. (1) Live workshop facilitation: SALUS HAZOP AI and Kairos Technology are cloud workspaces facilitators use during the study to capture nodes, deviations, and actions in real time. (2) Enterprise PHA register and documentation: Sphera PHA-Pro is the cloud-and-on-prem standard for tier-1 owner-operators running multi-asset PHA programmes with formal sign-off workflows. (3) Document extraction and register automation: Pathnovo extracts completed HAZOP study PDFs into structured registers mapped to current P&ID revisions, the workflow facilitation and PHA tools do not cover. Most teams end up combining one tool from each category. See the HAZOP software comparison for a fuller breakdown and the HAZOP register extraction page for the Pathnovo workflow.
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