Process Safety Consultant: PHA Lead & Risk Analysis

Jensen Hughes; Westborough (MA); On-site; USD 110,000 - 175,000; Full time

Job summary

Jensen Hughes is expanding its industrial safety practice with a dedicated focus on manufacturing and industrial clients—especially those with chemical processing, dust hazards, and high-hazard operations. We seek a Process Safety Consultant specialized in PHA to lead and support risk assessments and safety compliance projects.

The ideal candidate will have hands-on experience conducting, facilitating, and leading PHAs across industries, with strong communication and travel willingness to

Qualifications

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

Responsibilities

• Lead and perform Process Hazard Analyses (PHA) using HAZOP, What-If, LOPA and FMEA.
• Guide clients through PHA lifecycle management: methodology, pre-study, team coordination, study execution, documentation, follow-up.
• 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 hazard analysis.
• Prepare and peer-review 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.

Education

Bachelor’s degree in Chemical/Mechanical/Process Engineering

PHA leadership certification

Professional credentials (e.g., PE, FS Eng, FSP or CFSE)

Excellent verbal and written communication

Client management and proposal development

Willing to travel 25–50%

Tools

PHA software tools

Job description

Jensen Hughes is expanding its industrial safety practice with a dedicated focus on manufacturing and industrial clients—especially those with chemical processing, dust hazards, and high-hazard operations. We seek a Process Safety Consultant specialized in PHA to lead and support risk assessments and safety compliance projects.

The ideal candidate will have hands-on experience conducting, facilitating, and leading PHAs across industries, with strong communication and travel willingness to