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Senior Process Safety Engineer Jobs in Virginia (NOW HIRING)

Phlow Corp.

Process Engineer

Petersburg, VA · On-site

Advanced engineering position that leads in process design and execution. Provides mentorship to ... senior staff on process design. Implements new solutions for process safety, quality, and ...

Hensel Phelps

Safety Engineer

Tysons, VA · On-site

The Safety Engineer is a resource for supporting the safety manager and project team in the ... Participate in the six-step quality control/safety process including reviewing the activity hazard ...

Westrock

Staff Eng, Process Control

Covington, VA · On-site

... safety, loyalty, integrity and respect, we are committed to delivering meaningful value for shareholders, customers, employees and the communities where we operate. Position: Senior Process Engineer ...

Civica Rx

Process Engineer II (238)

Petersburg, VA · On-site

The Senior Process Engineer will act as a bridge between the project planning phase and ongoing operations by assuming System Owner responsibility for one or more manufacturing systems. In this role ...

Civica Rx

Process Engineer II (238)

Petersburg, VA · On-site

The Senior Process Engineer will act as a bridge between the project planning phase and ongoing operations by assuming System Owner responsibility for one or more manufacturing systems. In this role ...

KLDiscovery

Senior Manager, Process Engineer

Mclean, VA

$106K - $138K/yr

Senior Manager, Process Engineer - Operations | Reports to SVP, Operations KLDiscovery is hiring a Senior Manager, Process Engineer to build the industrial engineering function from the ground up.

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Senior Process Safety Engineer information

See Virginia salary details

$74.4K

$120.1K

$169K

How much do senior process safety engineer jobs pay per year?

As of Jun 17, 2026, the average yearly pay for senior process safety engineer in Virginia is $120,077.00, according to ZipRecruiter salary data. Most workers in this role earn between $103,100.00 and $133,300.00 per year, depending on experience, location, and employer.

What engineers make $300,000 a year?

Senior Process Safety Engineers in the chemical, oil and gas, or petrochemical industries can earn $300,000 or more annually, especially with extensive experience, specialized certifications, and leadership roles. High salaries are often associated with seniority, complex projects, and working in high-risk environments that require advanced knowledge of safety protocols and risk management tools.

What are the main challenges a Senior Process Safety Engineer faces when implementing new safety protocols across multiple facilities?

A Senior Process Safety Engineer often encounters challenges such as ensuring consistent application of safety standards across diverse sites, gaining buy-in from cross-functional teams, and adapting protocols to facility-specific hazards. Additionally, balancing regulatory compliance with operational efficiency requires strong communication and project management skills. Successfully addressing these challenges usually involves close collaboration with site managers, operations teams, and regulatory bodies, as well as ongoing training and audits to maintain high safety standards.

What are the key skills and qualifications needed to thrive as a Senior Process Safety Engineer, and why are they important?

To thrive as a Senior Process Safety Engineer, you need a solid background in chemical or process engineering, in-depth knowledge of process safety management (PSM), and typically a bachelor's degree in engineering with relevant certifications like CSP or CCPSC. Familiarity with process hazard analysis (PHA) tools, safety lifecycle software (such as PHA-Pro or BowTieXP), and regulatory standards (OSHA, API) is crucial. Strong analytical thinking, leadership, and effective communication skills help you guide multidisciplinary teams and convey complex safety issues clearly. These competencies are vital to ensure operational safety, regulatory compliance, and the prevention of major incidents in high-risk industrial environments.

What is the highest salary of a safety engineer?

The highest salary for a senior process safety engineer can exceed $150,000 annually, especially with extensive experience, advanced certifications, and working in high-demand industries such as oil and gas or chemical manufacturing. Top earners often have specialized skills in risk assessment, process hazard analysis, and safety management systems.

What engineer makes $500,000 a year?

Senior Process Safety Engineers in the chemical, oil and gas, or petrochemical industries can earn salaries approaching or exceeding $500,000 annually, especially with extensive experience, specialized certifications, and leadership roles. High compensation often reflects the critical safety responsibilities, technical expertise, and the complexity of the facilities they oversee.

How much do process safety engineers make in the US?

Process safety engineers in the US typically earn a median annual salary of around $90,000 to $110,000, with experienced professionals and those in senior roles earning over $130,000. Salaries vary based on location, industry, certifications, and years of experience, and the role often requires knowledge of safety standards and risk management tools.

What is the difference between Senior Process Safety Engineer vs Process Safety Engineer?

AspectSenior Process Safety EngineerProcess Safety Engineer
CertificationsTypically holds API, NEBOSH, or equivalent certificationsOften requires similar certifications, but less experience needed
Work EnvironmentLeads safety projects, mentors junior staff, and manages complex risk assessmentsSupports safety initiatives, conducts hazard analyses, and assists in safety documentation
Employer & Industry UsageCommon in oil & gas, chemical, and refining industriesUsed across similar industries, often as entry to mid-level role

The main difference between a Senior Process Safety Engineer and a Process Safety Engineer lies in experience, leadership responsibilities, and project scope. Senior professionals typically lead safety initiatives and mentor others, while Process Safety Engineers focus on supporting safety tasks and analysis. Both roles are vital for maintaining safety standards in high-risk industries.

What does a Senior Process Safety Engineer do?

A Senior Process Safety Engineer is responsible for ensuring that industrial processes, especially those involving hazardous materials, are designed and operated safely to prevent accidents and minimize risks. They analyze operations, conduct safety assessments, and implement systems to comply with safety regulations. Additionally, they lead incident investigations, develop safety procedures, and provide technical guidance to engineering teams to promote a strong safety culture within the organization.
What are the most commonly searched types of Process Safety Engineer jobs in Virginia? The most popular types of Process Safety Engineer jobs in Virginia are:
What are popular job titles related to Senior Process Safety Engineer jobs in Virginia? For Senior Process Safety Engineer jobs in Virginia, the most frequently searched job titles are:
What job categories do people searching Senior Process Safety Engineer jobs in Virginia look for? The top searched job categories for Senior Process Safety Engineer jobs in Virginia are:
What cities in Virginia are hiring for Senior Process Safety Engineer jobs? Cities in Virginia with the most Senior Process Safety Engineer job openings:
Senior Process Safety Engineer jobs near you
Infographic showing various Senior Process Safety Engineer job openings in Virginia as of June 2026, with employment types broken down into 1% Locum Tenens, 78% Full Time, 19% Part Time, 1% Contract, and 1% Nights. Highlights an 87% Physical, 5% Hybrid, and 8% Remote job distribution, with an average salary of $120,077 per year, or $57.7 per hour.
Process Engineer

Process Engineer

Phlow Corp.

Petersburg, VA • On-site

Full-time

Posted 27 days ago

Be an early applicant

Job description

Description:

Advanced engineering position that leads in process design and execution. Provides mentorship to less senior staff on process design. Implements new solutions for process safety, quality, and performance. Consults with management to implement production solutions. Implements high level of solutions and guidance based on experience. Work is highly independent.

Requirements:

• Follows listed PPE requirements and chemical handling requirements, addresses safety issues promptly, and communicates safety issues to fellow employees.

• Leads in the completion of Process Safety information and participates in Process Hazard Analysis. Conduct safety analysis to ensure that process is safe.

• Anticipates potential safety issues and proactively prevents safety events. Leads in the development of safe solutions to encountered safety problems.

• Uses engineering skills to design projects for enhanced safety, quality and or productivity improvements.

• Follows cGMP guidelines for operation comments and batch records, other change control requirements, and related documentation practices. Takes the lead in generation of GMP documentation and operator training.

• Involved in CAPA writing and implementation.

• Teaches junior engineers appropriate practices for addressing quality issues, including variances, activations, and other QA related documentation.

• Designs processes in current or future plant equipment using extensive plant and chemistry knowledge.

• Provides leadership in audits in the plant.

• Monitors and manages process performance.

• Conducts product changeovers, preparation of cleaning instruction, and leading in set up operations.

• Activates and qualifies facilities and equipment.

• Prepares new batch records and work instructions.

• Develops process training for all personnel.

• Troubleshoots processes to reduce downtime, improve cycle time, and increase productivity.

• Modifies piping and instrumentation drawings, flow sheets, and emission calculations.

• Independently evaluates, selects, and applies engineering techniques, procedures and criteria using judgement in making adaptations and modifications.

• Mentors less senior engineers for development.

• Communicates directly to management about process delays, issues, and improvements.

• Writes CEAs for process and plant improvements under direction from more experienced colleagues.

• Details process feedback to program managers and SLT.

• Provides input to the business plan and production plan.

• Experience in transferring technology from R&D scale to full scale production


Experience & Qualifications


• Typically requires 8-14 years of related experience and a bachelor's degree or 7-11 years of related experience and a master's degree or equivalent experience.

• Bachelor’s degree in chemical engineering or equivalent required

• At least one (1) year of relevant experience in a cGMP environment preferred.


Competencies & Skills


• Strong interpersonal and verbal communication skills

• Must have a high consciousness for personal safety

• Strong attention to detail

• Team oriented

• Highly self-motivated


Physical Requirements


  • Constantly required to see to utilize computer screens and monitors to perform job duties including reading & writing, as well as when presenting information and communicating with others.
  • Frequently required to talk or hear to communicate with employees, candidates, vendors, and others, including presenting information in front of groups.
  • Frequently required to reach with arms and hands performing repetitive motions and using finger dexterity to work primarily at a computer keyboard and with a mouse.
  • Frequently required to sit, and occasionally required to stand or walk to move around primarily in an office environment.
  • Occasionally lift and/or move up to 10 pounds.
  • This position may require up to 5% travel with occasional increase in travel demands based on business needs.