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Hazard identification and risk assessment: HIRA and JSA

Fire and Safety Engineering (B.E./B.Tech) · Industrial safety engineering · free study notes for exams, placements and interviews

In short

Hazard identification and risk assessment (HIRA) is the systematic process of finding everything in a workplace that can cause harm, judging how likely and how severe that harm is, ranking the results, and deciding what controls bring the risk down to an acceptable level. Job safety analysis (JSA), also called job hazard analysis, is the task-level version of the same logic: break a job into steps, list the hazards of each step, and fix controls for each hazard. HIRA is the mandatory first step of every safety management system — ISO 45001:2018 clause 6.1.2, the OSH&WC Code 2020 and its rules, the MSIHC Rules 1989 for hazardous chemical units, and every corporate safety audit protocol. It is examined in GATE-equivalent and university papers through risk matrices, risk scores, FMEA/RPN numbers and the hierarchy of control, and it is the single most asked topic in entry-level EHS interviews with Reliance, L&T, Tata Steel, Adani, Vedanta, ONGC, IOCL and construction and EPC contractors.

Explained

Basic vocabulary - get these exact

Hazard classification - the list examiners want

HIRA: the step-by-step method

  1. Define scope and boundaries: plant, area, process, activity, project phase; include routine, non-routine, maintenance, commissioning, shutdown, emergency and contractor work, and people other than employees (visitors, nearby public).
  2. Form the team: area in-charge, process/maintenance engineer, safety officer, a worker who actually does the job, plus a worker-representative member of the safety committee. Worker participation is a legal requirement for consultation and is what makes the output credible.
  3. Collect inputs: P&IDs, layouts, SDS (safety data sheets), operating and maintenance procedures, incident and near-miss history, audit and inspection findings, hygiene monitoring data, equipment manuals, statutory test certificates, legal register.
  4. Break the scope into activities: by process step, equipment, or job - the unit of entry in the HIRA worksheet.
  5. Identify hazards for each activity using structured aids: walk-through survey, checklists, what-if questions, energy-trace, HAZID/HAZOP outputs, task observation, worker interviews.
  6. Identify existing controls honestly - interlocks, guards, PPE, procedures, training, permits.
  7. Assess likelihood and severity on the organisation's agreed scales and compute the risk score / band.
  8. Evaluate against criteria: low / medium / high / extreme, with defined action and authority for each band.
  9. Decide additional controls using the hierarchy of control; name an owner and a target date.
  10. Re-score the residual risk with the proposed controls assumed in place and check it is acceptable.
  11. Record in the risk register, approve, and communicate to everyone affected.
  12. Implement, verify effectiveness, and review - periodically (commonly annually) and on triggers: process or plant change, new chemical or equipment, incident or near-miss, legal change, audit finding, new findings from monitoring.

JSA: the task-level method

Hazard identification techniques - and when each is right

Risk estimation: scales, matrices and scoring

Hierarchy of control and risk treatment

  1. Elimination - remove the hazard or the task (design out the need to work at height).
  2. Substitution - replace with something less hazardous (toluene for benzene, water-based for solvent-based paint).
  3. Engineering controls / isolation - enclosure, guarding, interlocks, local exhaust ventilation, intrinsically safe equipment, edge protection, relief and vent systems.
  4. Administrative controls - safe operating procedures, permit to work, lockout-tagout, job rotation, training and competence, signage, limiting exposure time, maintenance schedules.
  5. PPE - last line of defence; protects only the wearer, depends on fit, use and upkeep.
  6. Why the order: the top controls do not rely on human behaviour and do not degrade; the bottom two fail silently. Many corporate standards show substitution combined with elimination and add "isolation/separation" as a separate level - the five-level list above is the usual exam answer.
  7. Controls must also be checked for new hazards introduced (a guard that traps heat, an LEV that discharges into a walkway) and for reliability - a safety-critical control needs inspection, testing and a performance standard.
  8. Interim controls are allowed while an engineering fix is being procured, and must be recorded with a date.

Indian legal and standards framework (as of November 2026)

Key points

Formulas and examples

Risk R = L × S — L = likelihood rating (1-5, dimensionless), S = severity rating (1-5, dimensionless); R = 1 to 25, a dimensionless ordinal score
Fine-Kinney R = C × E × P — C = consequence (1, 3, 7, 15, 40, 100), E = exposure (0.5 rare … 10 continuous), P = probability (0.1 practically impossible … 10 expected); R is dimensionless
FMEA RPN = S × O × D — S = severity, O = occurrence, D = detection difficulty, each 1-10; RPN = 1 to 1000
Risk reduction factor RRF = Initial risk score / Residual risk score; % risk reduction = (1 − R_res/R_init) × 100
Individual risk per annum IRPA = Σ (f_i × P_fatality,i) — f_i = frequency of scenario i (per year), P = conditional probability of fatality; units: fatalities per person per year
Expected (monetary) loss EML = f × C — f = event frequency (per year), C = loss per event (₹); EML in ₹ per year
Fatal accident rate FAR = (number of fatalities / total exposed hours) × 10⁸ — fatalities per 10⁸ exposed hours
AND gate: P(top) = P1 × P2 … (independent events); OR gate: P(top) = 1 − (1 − P1)(1 − P2) … ≈ P1 + P2 for small P

Example 1 - 5 × 5 matrix, initial and residual risk. A 25 kg bag of additive is manually lifted from floor level to a 1.4 m hopper, 180 times per shift.

Example 2 - Fine-Kinney score for hot work on a tank farm pipeline.

Example 3 - FMEA / RPN on a centrifugal pump mechanical seal.

Failure modeSODRPN
Seal face wear → hydrocarbon leak → fire945180
Bearing failure → vibration → shaft seizure73363
Coupling misalignment → vibration55250
Casing gasket blow-out → spray release926108

Example 4 - fault tree and expected loss for a conveyor guard. A nip-point injury needs (a) the guard to be missing or defective AND (b) a person to reach into the nip.

Example 5 - FAR for a construction site. 1,200 workers × 8 hours/day × 300 days = 28,80,000 (2.88 × 10⁶) exposed hours in a year, with 2 fatalities.

Comparison table

HIRAJSAHAZOPFMEAQRA
Unit of studyActivity / area / processJob stepProcess node and parameter deviationComponent failure modeScenario
DirectionBothForward through the taskDeviation-based, guideword-ledBottom-upBottom-up, numeric
OutputRisk register, risk bandsSafe step-by-step method, permit inputDeviations, causes, safeguards, actionsRPN priority listIRPA, F-N curve, risk contours
EffortMediumLowHigh (team, days)Medium-highVery high
Who uses itWhole site, all industriesSupervisor and crewContinuous process plantsEquipment and reliabilityMAH installations, statutory safety report
NatureQualitative / semi-quantitativeQualitativeQualitativeSemi-quantitativeQuantitative

Where it is used

Interview questions

Common mistakes

Related topics

Process plant safety: HAZOP and PSM · Safety instrumented systems · Fire, explosion and toxic release hazards · Construction safety · Industrial safety and maintenance · Electrical safety and earthing

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