Hazard Identification and Risk Assessment (HIRA): Complete Framework and Practical Examples
Author: Bala (Cert IOSH) OHSMS Expert
Hazard
Identification and Risk Assessment (HIRA): Complete Framework and Practical
Examples
In high-risk industries such as construction,
manufacturing, oil & gas, power plants, logistics, and chemical processing,
uncontrolled hazards directly translate into injuries, fatalities, legal
liabilities, and reputational loss. A structured HIRA process is
therefore not a paperwork exercise — it is a systematic decision-making tool
to eliminate or control risk before harm occurs.
This complete framework explains:
- Step-by-step hazard identification
- Structured risk assessment methodology
- Real industrial examples
- Risk matrix tools
- Practical control strategies
1. What is HIRA?
Hazard Identification and Risk Assessment (HIRA) is a systematic method
used to:
- Identify workplace hazards
- Evaluate the level of risk
- Implement control measures
- Monitor effectiveness
It forms the backbone of proactive safety management
systems aligned with:
- International Organization for Standardization – ISO 45001
- Occupational Safety and Health Administration (OSHA)
- National Fire Protection Association (NFPA standards for fire risk)
2. Understanding
Key Concepts
2.1 Hazard
A hazard is anything with the potential to
cause injury, illness, property damage, or environmental harm.
Examples:
- Unguarded rotating shaft
- Acid handling
- Working at height
- Confined space entry
- Electrical panel maintenance
2.2 Risk
Risk = Likelihood × Severity
Risk represents the probability that a hazard will
cause harm and the seriousness of that harm.
3. Types of
Hazards in Industry
1. Physical Hazards
Noise, vibration, radiation, heat stress, slips,
falls.
2. Chemical Hazards
Acids, solvents, fumes, dust, gases.
3. Biological Hazards
Bacteria, viruses, contaminated waste.
4. Ergonomic Hazards
Manual handling, awkward posture, repetitive motion.
5. Mechanical Hazards
Moving machinery, rotating parts, pinch points.
6. Electrical Hazards
Shock, arc flash, short circuits.
7. Psychosocial Hazards
Stress, fatigue, harassment, shift work.
4. Complete HIRA
Process (Step-by-Step Framework)
Step 1: Define Scope of Assessment
Before starting hazard identification, clearly define:
- Work activity
- Department
- Equipment involved
- Number of workers exposed
- Environmental conditions
Example:
“Maintenance activity inside chemical reactor during
shutdown.”
Step 2: Hazard Identification
Methods Used
- Workplace inspection
- Job Safety Analysis (JSA)
- Process review
- Incident history review
- Worker interviews
- Safety data sheet (SDS) review
- Regulatory compliance review
Questions to Ask
- What can go wrong?
- Who can be harmed?
- How can harm occur?
- Under what conditions?
Step 3: Determine Who Might Be Harmed
- Employees
- Contractors
- Visitors
- Public
- Environment
Step 4: Risk Assessment
Risk Rating Formula
Risk Score = Likelihood × Severity
Likelihood Scale
|
Rating |
Description |
|
1 |
Rare |
|
2 |
Unlikely |
|
3 |
Possible |
|
4 |
Likely |
|
5 |
Almost Certain |
Severity Scale
|
Rating |
Description |
|
1 |
Minor Injury |
|
2 |
First Aid |
|
3 |
Medical Treatment |
|
4 |
Major Injury |
|
5 |
Fatality |
Risk Matrix
Risk Levels:
- 1–5 → Low
- 6–10 → Medium
- 11–15 → High
- 16–25 → Extreme
5. Hierarchy of Controls
- Elimination
- Substitution
- Engineering Controls
- Administrative Controls
- PPE
Priority is always top-down.
6. Real
Industrial Example 1 – Construction (Working at Height)
Activity:
Scaffolding erection at 15 meters.
Hazard Identification:
- Fall from height
- Falling materials
- Scaffold collapse
Risk Assessment:
|
Hazard |
Likelihood |
Severity |
Risk |
|
Fall |
4 |
5 |
20 (Extreme) |
Control Measures:
Engineering Controls
- Guardrails
- Toe boards
- Scaffold certification
Administrative Controls
- Work permit
- Competent supervision
- Toolbox talk
PPE
- Full body harness
- Double lanyard
Residual Risk: 8 (Medium)
7. Real
Industrial Example 2 – Chemical Industry
Activity:
Handling concentrated sulfuric acid.
Hazards:
- Chemical burn
- Inhalation
- Spill reaction
Risk Score Before Control:
Likelihood = 3
Severity = 5
Risk = 15 (High)
Control Measures:
- Closed transfer system
- Secondary containment
- Spill kit
- Emergency shower
- Chemical resistant PPE
Residual Risk: 6 (Medium)
8. Real
Industrial Example 3 – Manufacturing (Machine Guarding)
Activity:
Operating CNC machine.
Hazard:
Hand entanglement in rotating shaft.
Initial Risk:
Likelihood = 3
Severity = 4
Risk = 12 (High)
Controls:
- Fixed guard
- Interlocking system
- Emergency stop
- Operator training
Residual Risk:
Likelihood = 2
Severity = 4
Risk = 8 (Medium)
9. Common HIRA Tools
- Job Safety Analysis (JSA)
- What-If Analysis
- HAZOP
- Checklists
- Failure Mode Effect Analysis (FMEA)
- Bow-Tie Analysis
- Fault Tree Analysis
Risk Rating
Reference Sheet
Likelihood Scale:
1 Rare
2 Unlikely
3 Possible
4 Likely
5 Almost Certain
Severity Scale:
1 Minor
2 First Aid
3 Medical
4 Major
5 Fatal
11. Example
Filled HIRA Table
|
Sl No |
Activity |
Hazard |
Consequence |
L |
S |
Risk |
|
1 |
Welding |
Arc Flash |
Eye damage |
3 |
3 |
9 |
|
2 |
Forklift |
Collision |
Fracture |
4 |
4 |
16 |
|
3 |
Confined Space |
Oxygen Deficiency |
Fatality |
3 |
5 |
15 |
12. Monitoring
& Review
HIRA must be reviewed:
- After incident
- Process change
- Equipment change
- New chemical introduction
- Annually
- After legal update
13. Common
Mistakes in HIRA
- Copy-paste assessments
- Ignoring contractor activities
- No worker consultation
- Not updating after change
- Over-reliance on PPE
- No residual risk evaluation
14. Advanced HIRA
Integration
Modern industries integrate HIRA with:
- Permit to Work System
- Behavioural Safety
- ISO 45001 Management System
- Digital risk software
- KPI monitoring
15. Key
Performance Indicators (KPIs)
- % High risk activities reduced
- Near miss reporting rate
- Corrective action closure rate
- Audit findings trend
- Lost Time Injury Frequency Rate
16. Practical
Implementation Strategy
For successful implementation:
- Management commitment
- Competent assessors
- Worker participation
- Training
- Documentation
- Continuous improvement
17. Final Expert
Guidance
An effective HIRA process is not a document—it is a live control mechanism that anticipates failure before it
occurs.
A competent safety professional ensures:
- Hazards are identified systematically
- Risks are evaluated objectively
- Controls follow hierarchy
- Residual risks are justified
- Reviews are continuous
When properly applied, hazard identification and
structured risk assessment reduce accidents, improve productivity, enhance
compliance, and protect organizational reputation.
