Look for "HazOp & HazAn" by Dr. Trevor Kletz in the on-line bookshop. Order a copy, perhaps?
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"Did you get my e-mail?" - "The biggest problem in communication is the illusion that it has taken place" - George Bernard Shaw, 1856
If possible, try to find some templates from a trade association involving boilers/heaters/furnaces. There may already be some "canned" approaches you can use.
[I work in ammonia refrigeration. In that world, the IIAR (International Association of Ammonia Refrigeration) has generated sample PHAs (Process Hazard Analyses) with about 400 what-if/checklist scenarios pertaining to generally recognized hazards in that field. The what-if and checklist methods, and some others, are recognized by OSHA. Maybe a similar resource exists in your field.]
The OSHA regulation covering this is actually quite sensible, though rather complex. When it came into force there was a flurry of panicked activity to comply (late 80s -mid 90s, mostly). This resulted in some awkward PHAs, fallout from which still persists, in the form of really anal questions and procedures. Thus, even if some canned materials are available, it will pay to look at several approaches to find a good fit.
One of the good softwares for this is Hazard Review Leader, by the ABS (American Bureau of Shipping).
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HAZOP STUDY
Re: HAZOP STUDY
