Job Summary

The Process Safety Consultant is a full-time, remote role with regular travel to client sites. This position works directly with industrial clients to build, evaluate, and strengthen their process safety programs. Day-to-day tasks include leading and documenting Compliance Audits against OSHA PSM (29 CFR 1910.119) and EPA RMP (40 CFR Part 68) requirements, facilitating and scribing PHAs, conducting Mechanical Integrity audits, and developing complete PSM and RMP programs for new and existing facilities. The consultant will review written programs, operating procedures, training records, and inspection and maintenance documentation, then deliver clear findings and practical recommendations that help clients close gaps and stay compliant. The role also involves supporting clients through EPA and OSHA inspections and partnering with Macha PSM's engineering team when projects require P&ID development, relief system evaluations, or other technical calculations.

 

We are open to candidates in any location in the U.S. In particular, we are looking for consultants in the following regions:

• California

• Wisconsin

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Responsibilities

• Plan, conduct, and document PSM and RMP Compliance Audits, including site walkthroughs, employee interviews, and records review.

• Facilitate or scribe PHAs using methods such as HAZOP, What-If, and Checklist analysis, and track recommendations through to closure.

• Perform Mechanical Integrity audits, evaluating inspection, testing, and preventive maintenance programs against applicable codes and RAGAGEP (e.g., IIAR standards for ammonia refrigeration).

• Develop full PSM/RMP program buildouts, including written programs, operating procedures, MOC, incident investigation, emergency response, and training components.

• Prepare clear, well-organized reports and deliverables tailored to each client's operation.

• Assist clients with preparation for, and responses to, regulatory inspections and citations.

• Build strong client relationships and serve as a trusted point of contact throughout each project.

 

Qualifications

• Strong working knowledge of Process Safety Management, including all 14 elements of OSHA PSM and EPA RMP program requirements.

• Hands-on experience conducting compliance audits, facilitating or participating in PHAs, and evaluating Mechanical Integrity programs.

• Experience developing or maintaining written PSM/RMP programs and operating procedures.

• Bachelor's degree in engineering, occupational safety, chemistry, or a related field, or equivalent industry experience.

• Experience in industrial or manufacturing environments, preferably ammonia refrigeration, petrochemical, or similar process industries.

• Ability to read and interpret P&IDs and technical documentation.

• Excellent technical writing skills with strong attention to detail and documentation quality.

• Confident communication and facilitation skills, with the ability to lead meetings with plant operators, maintenance staff, and management.

• Ability to work independently and manage your own schedule in a remote setting.

• Willingness to travel to client sites as needed and to work safely in field and plant environments.

• Professional certifications such as CSP, CCPSC, or ammonia refrigeration credentials (e.g., IIAR, RETA CARO/CIRO) are a plus.

 

Requirements

• Communication • Excellent - Strong

• Attention to Detail • Strong - Strong

• Team Collaboration • Strong - Strong

• Work Ethic • Excellent - Strong

 

Nice to Have

• Industrial Systems • 2 - 3 years

• Process Safety Management • 1 - 3 years

• Client Relationship Management • 1 - 3 years

 

About Us

Macha PSM is a specialized process safety consulting and engineering firm serving a wide range of industrial facilities. The team supports clients from small cold storage operations to some of the largest global corporations, providing tailored safety and engineering solutions. Services include innovative Process Safety Management (PSM) program development, Compliance Audits, Process Hazard Analyses (PHAs), and support during EPA and OSHA inspections. The engineering team offers capabilities such as full P&ID development, relief vent analysis, inventory calculations, ventilation assessments, and material and energy balance calculations. With offices in Huntsville, Alabama, and Moscow, Idaho, Macha PSM is focused on delivering high-quality, client-centered process safety services.