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Senior Process Safety Engineer Jobs in Virginia (NOW HIRING)

Phlow Corp

Process Engineer

Petersburg, VA · On-site

$100K - $150K/yr

  • Medical

  • Life

  • Retirement

  • PTO

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 ...

Phlow Corp.

Process Engineer

Petersburg, VA · On-site

$100K - $150K/yr

  • Medical

  • Life

  • Retirement

  • PTO

... senior staff on process design. Implements new solutions for process safety, quality, and ... Uses engineering skills to design projects for enhanced safety, quality and or productivity ...

Smurfit Westrock

Sr. Mgr, Safety

Covington, VA · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Support Process Safety Management (PSM) compliance and performance. * Lead contractor safety ... Bachelor's degree in safety, engineering, industrial hygiene, or a related technical field ...

Smurfit Westrock

Staff Eng, Process Control

Covington, VA · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

... 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 ...

Westrock

Staff Eng, Process Control

Covington, VA · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

... 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

$115K - $145K/yr

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

$115K - $145K/yr

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 ...

Novo Nordisk

Senior Process Engineer - API manufacturing

Petersburg, VA · On-site

$102K - $132K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Position The Process Engineer position will support the site to onboard new API manufacturing ... Follow all safety and environmental requirements in the performance of duties * Other duties as ...

Novo Nordisk

Senior Process Engineer - API manufacturing

Petersburg, VA · On-site

$102K - $132K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Position The Process Engineer position will support the site to onboard new API manufacturing ... Follow all safety and environmental requirements in the performance of duties * Other duties as ...

IPL (Indiana)

Senior BESS Product Safety Engineer

Richmond, VA · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Senior BESS Product Safety Engineer is a core technical authority for BESS safety architecture ... Experience supporting permitting, testing, and regulatory approval processes. * Proficiency with ...

Novo Nordisk

Senior Process Engineer - API manufacturing

Petersburg, VA · On-site

$102K - $132K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The Position The Process Engineer position will support the site to onboard new API manufacturing ... Follow all safety and environmental requirements in the performance of duties * Other duties as ...

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All JobsProcess Safety Engineer JobsSenior Process Safety Engineer JobsSenior Process Safety Engineer Jobs in Virginia

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 Aug 13, 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 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 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 August 2026, with employment types broken down into 1% As Needed, 80% Full Time, 16% Part Time, 2% Contract, and 1% Nights. Highlights an 99% Physical, and 1% Remote job distribution, with an average salary of $120,077 per year, or $57.7 per hour.

Process Engineer

Phlow Corp

Petersburg, VA • On-site

$100K - $150K/yr

Full-time

Medical, Life, Retirement, PTO

Re-posted 11 days ago

Job 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.

The salary range for this position is $100,000 to $150,000, with the final offer determined based on factors such as the candidate's experience, qualifications, skills, and education. In addition to a competitive base salary, this position is eligible to participate in Phlow's bonus and stock option programs. Phlow also offers a comprehensive benefits package that includes medical, life, and disability insurance; retirement savings plans; paid time off and company holidays; and education-related benefits. Many of these programs are fully funded or significantly subsidized by the company, reflecting our commitment to supporting the health, well-being, and professional development of our employees.

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