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Senior Process Safety Engineer Jobs in Madison, AL

Astrion

Senior System Safety Engineer SME

Huntsville, AL · On-site

$180K - $215K/yr

Overview Senior System Safety Engineer SME JOB LOCATION: Huntsville, AL JOB STATUS: Full Time Clearance: Secret Travel: Up to 25% The Portfolio Acquisition Executive for Fires (PAE-F) seeks a Senior ...

AeroVironment

Sr. Staff Safety Engineer

Huntsville, AL · On-site

Worker Type Regular Summary We are seeking an experienced Senior Staff Safety Engineer to lead ... Drive continuous improvement of system safety processes, templates, tools, and training within the ...

Leidos

System Safety Engineer

Huntsville, AL

$107K - $195K/yr

Experience with AS9100 and quality system processes * Knowledge of Safety and Reliability Engineering methods * Understanding of NASA review processes and preparation * Object Management Group (OMG ...

QTEC Aerospace

SYSTEMS SAFETY ENGINEER

Huntsville, AL · On-site

QTEC Aerospace is seeking a SYSTEMS SAFETY ENGINEER to join our team of professionals in Huntsville, AL. The qualified applicant will become part of a team of professionals representing both industry ...

Enhance Recruiting

Process Engineer

Decatur, AL · On-site

Support Process Safety Management (PSM), Risk Management Program (RMP), and regulatory compliance ... Develop engineering studies, economic evaluations, and capital project recommendations.

IGNITE

RANGE SAFETY ENGINEER

Huntsville, AL · On-site

Job Title RANGE SAFETY ENGINEER Location Huntsville, AL 35806 US (Primary) Category Engineering Job ... process. Please send your request to IgniteHR@IgniteNow.Net

Starfish

Senior Software Safety Engineer

Huntsville, AL · On-site

$120K - $159K/yr

Our team provides superior research, development, and engineering services to the Federal ... Defines safety strategies, processes, and best practices across programs. * Supports major system ...

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All JobsProcess Safety Engineer JobsSenior Process Safety Engineer JobsSenior Process Safety Engineer Jobs in Madison, AL

Senior Process Safety Engineer information

See Madison, AL salary details

$67.2K

$108.5K

$152.8K

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

As of Aug 7, 2026, the average yearly pay for senior process safety engineer in Madison, AL is $108,517.00, according to ZipRecruiter salary data. Most workers in this role earn between $93,200.00 and $120,500.00 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 popular job titles related to Senior Process Safety Engineer jobs in Madison, AL? For Senior Process Safety Engineer jobs in Madison, AL, the most frequently searched job titles are:
What cities near Madison, AL are hiring for Senior Process Safety Engineer jobs? Cities near Madison, AL 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 Madison, AL as of August 2026, with employment types broken down into 93% Full Time, and 7% Contract. Highlights an 91% In-person, and 9% Remote job distribution, with an average salary of $108,517 per year, or $52.2 per hour.

Senior System Safety Engineer SME

Astrion

Huntsville, AL • On-site

$180K - $215K/yr

Full-time

Posted 7 days ago

Job description

Overview

Senior System Safety Engineer SME

JOB LOCATION: Huntsville, AL

JOB STATUS: Full Time

Clearance: Secret

Travel: Up to 25%


The Portfolio Acquisition Executive for Fires (PAE-F) seeks a Senior System Safety Engineer Subject Matter Expert (SME) to support the Strategic and Operational Rockets and Missiles (STORM) project office located at Redstone Arsenal in Huntsville, AL.

REQUIRED QUALIFICATIONS / SKILLS

  • Must be able to obtain and maintain a DoW security clearance.
  • Bachelor of Science (BS) in Engineering, Science, Math, Management, Business or related weapon system discipline.
  • 25 years relative experience.
  • Excellent customer interface and communications skills, written and verbal.
  • Willingness to travel, up to 25%.

PREFERRED QUALIFICATIONS / SKILLS

  • Master of Science (MS) in Engineering, Science, Math, Management, Business or related weapon system discipline.
  • 30 years relative experience.
  • Experience in the preparation, review, and input to safety related technical data packages and presentation materials for government safety review boards, including the U.S. Army Fuze Safety Review Board (AFSRB); Ignition System Safety Review Board (ISSRB); Software Systems Safety Technical Review Panel (SSSTRP); U.S. Navy Fuze and Initiation System Technical Review Panel (FISTRP); U.S. Navy Weapon System Explosives Safety Review Board (WSESRB), Joint Services Insensitive Munitions Technical Panel (JSIMTP), Joint Services Software Safety Authorities (JS-SSA), and other safety reviews to obtain Government safety approval.
  • Experience in developing input to contract documents, such as Statements of Work and Performance Specifications to ensure system safety considerations and requirements are properly addressed.
  • Experience in conducting and managing a System Safety Working Group (SSWG) or Safety Integrated Product Team (SIPT).
  • Active U.S. Government SECRET security clearance.

RESPONSIBILITIES

  • Lead the application and management of a System Safety Program for multiple weapons and combat systems’ full life cycles IAW AR 385-10, MIL-STD-882E, DA PAM 385-16, AMCOM Regulation 385-17, and the Joint Software System Safety Engineering Handbook (JSSSEH).
  • Conduct system safety assessments and hazard analyses of hardware and software in a variety of DoW weapons and combat systems (missiles, rockets, launchers, vehicles, and fire control systems) and related support equipment.
  • Prepare and/or review System Safety Management Plans (SSMPs), System Safety Program Plans (SSPPs) and Software System Safety Program Plans (SwSSPPs).
  • Prepare, update, and/or review contractor Safety Assessment Reports (SARs), Hazard Analyses, and System Safety Risk Assessments (SSRAs).
  • Conduct and/or review system safety assessments of new, updated, and/or modified weapon/combat system hardware and software, including change, waiver, variation, and exemption requests.
  • Assess system design documentation for development of system safety related requirements.
  • Conduct or evaluate System Requirements Hazard Analyses (SRHAs) to ensure all hazards are traced to system requirements and to add requirements necessary to mitigate existing hazards.
  • Assess system compliance with published design requirements including, but not limited to MIL-STD 1316, MIL-STD-1901, JOTP-050, JOTP-051, and MIL-STD-1472.
  • Assess system for safety specific test requirements and compliance with MIL-STD-810, MIL-STD-2105, MIL-STD-331, MIL-STD-464, MIL-STD-461, MIL-DTL 23659, JOTP-052, JOTP-053, TB-700-2, STANAG 2921, STANAG 4382, and others as required.
  • Assess system test data to verify/validate system safety requirements and mitigation controls.
  • Conduct and/or evaluate software system safety assessments including but not limited to Functional Hazard Analyses (FHAs), development of Software Control Categories (SCCs), Software Criticality Indexes (SwCIs), and software Level of Rigor (LoR) activities.
  • Successfully present system safety cases to Army and Joint Safety Boards.
  • Obtain Explosive Ordinance Disposal certifications for missile systems.
  • Experience in successfully obtaining all safety functional area materiel release documentation in support of Army/Joint combat systems and munitions in accordance with AR 770-3.
  • Author and gain AMCOM approval to transmit Ground Safety Alert Messages (GSAMs) and Safety of Use Messages (SOUMs) as needed to alert units of hazards discovered after fielding of munitions or missile launch vehicles.
  • Meet and/or coordinate with Government and/or contractor system engineers, software engineers, technical and test agency personnel, and Safety Office representatives to review system safety-related documentation, test reports, test data, and theater incident data to assess/coordinate safety implications and risk levels to Users.
  • Represent the safety functional area through direct coordination with senior project office leadership, the AMCOM safety director, Portfolio Management Executive (PME), and Portfolio Acquisition Executive (PAE) staff.
  • Review and/or provide input to contract documents such as Statements of Work and Performance Specifications to ensure safety considerations are properly addressed.

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