Sr. Process Safety Consultant

About the Company

For over 80 years, Jensen Hughes has been a global leader in fire protection engineering and closely related security and risk-based fields. Our expertise spans accessibility consulting, risk analysis, process safety, forensic investigations, security risk consulting, emergency management, and digital innovation. We collaborate to solve complex safety and security challenges, helping clients protect lives, property, and reputations. Our culture prioritizes trust, integrity, and professional growth, fostering a connected environment where employees can learn, grow, and succeed together.

About the Role

Jensen Hughes is expanding our industrial safety practice to address complex challenges for manufacturing and industrial clients, particularly those with chemical processing, combustible dust, and high-hazard operations. We are seeking a Process Safety Consultant specializing in Process Hazard Analysis (PHA) to lead and support risk assessment and safety compliance projects. This client-facing role is ideal for experienced professionals passionate about applying PHA methodologies to identify and mitigate operational risks, improve facility safety, and ensure regulatory compliance.

Responsibilities

• Lead and perform Process Hazard Analyses (PHA) using methodologies such as HAZOP, What-If, LOPA, and FMEA.
• Guide clients through the PHA lifecycle, including methodology selection, pre-study preparation, team coordination, study execution, documentation, and follow-up recommendations.
• Provide consulting on flammable liquids, reactive chemistry, and other high-hazard materials.
• Analyze process safety information (P&IDs, PFDs, material data, operating procedures) to support thorough and accurate hazard analysis.
• Prepare and peer-review high-quality, technically sound PHA reports for clients and regulatory authorities.
• Conduct site visits to evaluate risk and compliance with NFPA, OSHA PSM, and insurer standards.
• Support proposal development and participate in client-facing engagements to scope new PHA and process safety work.

Qualifications

• Bachelor’s degree in Chemical, Mechanical, or Process Engineering (or related field).
• 5+ years of experience in a process safety role with direct involvement in conducting or facilitating PHAs.
• Recognized certification in PHA leadership.
• Professional credentials (e.g., PE, Functional Safety competence such as FS Eng, FSP, or CFSE) are highly regarded.
• Excellent verbal and written communication skills, with the ability to clearly convey complex technical concepts.
• Experience with client management and proposal development is a plus.
• Willing to travel 25–50% for client engagements and on-site PHA sessions.

Desired Expertise

• High competency in one or more PHA software tools.
• Strong familiarity with key regulations and standards, including:
  • Process Safety Management Regulation (CFR 1910.119).
  • Risk Management Program (40 CFR Part 68 – Chemical Accident Prevention).
  • CCPS Guidelines for Hazard Evaluation Procedures.
  • IEC 61882 – Hazard and operability studies - Application guide.
  • IEC 61511-1:2016, Functional safety - Safety instrumented systems for the process industry sector.
• Understanding of safety instrumented systems and controls (a plus).
• Previous engineering experience in industries such as oil and gas, chemical, pulp and paper, industrial gases, or pharmaceutical.
• Experience performing consequence and frequency analysis for accidental toxic or flammable material releases.
• Design and analysis of pressure relief systems and governing codes/standards.
• Design and analysis of safety instrumented systems, including SIL Assignment, SIL verification, and Functional Safety Assessments.
• Knowledge of industrial instrumentation and control systems.
• Experience developing, implementing, or auditing PSM programs compliant with US OSHA and EPA Regulations or their international equivalents.

Pay

National pay range: $110,000—$175,000 USD.

Benefits

Jensen Hughes offers a competitive total rewards package, including a retirement plan, healthcare coverage, and a broad range of other benefits. Incentives and benefit packages may vary depending on the position and location.