Sr. Process Safety Consultant

Jensen Hughes•Chicago, GA

3d•Hybrid

About The Position

JENSEN HUGHES is expanding its industrial safety practice with a dedicated focus on solving complex challenges for manufacturing and industrial clients—particularly those with significant chemical processing, combustible dust, and high-hazard operations. We are currently seeking a Process Safety Consultant with a specialization in Process Hazard Analysis (PHA) to lead and support a growing portfolio of risk assessment and safety compliance projects. This is a strategic, client-facing opportunity for experienced professionals who are passionate about applying PHA methodologies to identify and mitigate operational risks, improve facility safety, and ensure regulatory and code compliance. The ideal candidate will have hands-on experience conducting, facilitating, and leading PHAs across various industries.

Requirements

Bachelor’s degree in Chemical, Mechanical, or Process Engineering (or related field)
5+ years of experience in process safety role with direct involvement in conducting or facilitating PHAs.
High competency in use of one or more PHA software tools.
Strong familiarity with key regulations and standards including: Process Safety Management Regulation, CFR1910.119 Risk Management Program (40CFR Part 68 – Chemical Accident Prevention) Guidelines for Hazard Evaluation Procedures, published by CCPS 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 one or more of the following industries: 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 the various governing codes and standards used in industry.
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.
Excellent verbal and written communication skills, with ability to clearly convey complex technical concepts.

Nice To Haves

Professional credentials (e.g., PE,. Functional safety competence such as FS Eng, FSP or CFSE is highly regarded)
Experience with client management and proposal development is a plus.

Responsibilities

Lead and perform Process Hazard Analyses (PHA) using methodologies such as HAZOP, What-If, LOPA and FMEA
Guide clients through PHA lifecycle management , including PHA methodology, 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.