Experienced EHS and Process Safety Leadership for Complex Industrial Operations

Brian Carr

Founder and Principal Consultant

Built Inside Industry, Not Outside It

Appalachian EHS & Process Safety Consulting is led by Brian Carr, an EHS and Process Safety professional with more than 30 years of experience in military, aerospace, chemical manufacturing, heavy industry, port operations, industrial startups, and commissioning support. Brian’s experience is not limited to advising organizations from the outside. He has owned EHS, PSM, and environmental management programs and has been accountable for making them work in operating facilities.

Brian is a veteran of the US Army and his background includes 15 years as an Aviation Safety Officer, first in the Army then as a DOD contractor, applying formal risk management, human factors in mishap prevention, incident investigation, operational controls, and safety leadership in high-consequence aviation environments around the world. He is also an FAA-certificated Private Pilot and Remote Pilot.

Experience That Goes Beyond Advice

Brian has built regulator-tested EHS and PSM programs from the ground up, established management of change, pre-startup safety review, and mechanical integrity and quality assurance systems, developed action-tracking processes, and integrated robust tools into reliability programs. He has developed technical libraries incorporating API, ASME, NBIC, NFPA, CGA, OSHA, and other applicable requirements and mentored engineers with no previous PSM experience.

His environmental experience includes air, water, soil and groundwater, waste, RCRA, SARA, greenhouse gas, the WV AST Act, RMP compliance, and environmental management system responsibilities. Brian has led multiple organizations through Responsible Care Management System implementation and successful RC14001 certification.

His programs have been tested through audits and inspections by the U.S. Department of Homeland Security, U.S. Coast Guard, WVDEP, federal OSHA, and North Carolina OSHA, including unscheduled PSM inspections that resulted in zero citations or penalties.

Brian has supported organizations through union grievances, employee complaints, serious-incident response, and OSHA investigations. His work has included evidence preservation, document review, management preparation, corrective-action development, and the successful resolution of OSHA allegations that were not substantiated by the available evidence.

A Practical Approach

Brian does not believe that handing a client a binder is the same as building a program. Effective programs must be technically sound, understandable to the people responsible for using them, and integrated into daily operations. Appalachian EHS focuses on clear ownership, practical procedures, disciplined action closure, measurable performance, and systems that continue working after the engagement ends.

Professional Qualifications

• EHS and PSM program leadership in high-hazard operations

  • Behavior-Based Safety Systems (BBS)

  • Human & Organizational Performance (HOP)

• Certified Machinery Safety Expert (CMSE)

• OSHA Authorized Outreach Trainer

• RC14001 and management-system implementation experience

• Internal, second-party, and third-party auditor experience

• ABS Group Root Cause Analysis and Incident Investigation training

• Laser Safety Officer

• BLS Instructor

• TWIC