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Senior Process Safety Engineer Jobs in Madison, AL

As a Principal System Safety Engineer, you will be accountable for the establishment and execution ... Relocation Eligible As part of our commitment to maintaining a secure hiring process, candidates ...

You will help maintain safety and process assurance objectives for electronic hardware; work with systems/software/hardware responsible engineers to identify and verify compliance with safety ...

... safety approval processes. * Experience managing a safety program and collaborating with ... of engineering functions to identify and mitigate risks. * Ability to obtain and maintain a Secret ...

Working knowledge of systems engineering principles and processes * Verification experience or ... System Safety Engineering experience conducting comprehensive system safety analyses IAW MIL-STD ...

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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 Sep 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 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 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 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 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 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:

Infographic showing various Senior Process Safety Engineer job openings in Madison, AL as of August 2026, with employment types broken down into 1% As Needed, 72% Full Time, 22% Part Time, 1% Temporary, 2% Contract, and 2% Nights. Highlights an 96% Physical, and 4% Remote job distribution, with an average salary of $108,517 per year, or $52.2 per hour.

Principal Safety Engineer

Raytheon

Huntsville, AL • On-site

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 19 days ago


RTX rating

8.2

Company rating: 8.2 out of 10

Based on 86 frontline employees who took The Breakroom Quiz

38th of 72 rated aerospace companies


Job description

Date Posted:

2026-06-11

Country:

United States of America

Location:

US-AL-HUNTSVILLE-315 ~ 315 Bob Heath Dr ~ BOB HEATH

Position Role Type:

Onsite

U.S. Citizen, U.S. Person, or Immigration Status Requirements:

The ability to obtain and maintain a U.S. government issued security clearance is required.​ U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance

Security Clearance Type:

DoD Clearance: Secret

Security Clearance Status:

Active and existing security clearance required after day 1

At RTX, the world's largest aerospace and defense company, 185,000 great minds are united by purpose and inspired to make a difference solving the world’s most complex problems. With our three market leading businesses, world-class operations and investments in research and development, we offer capabilities and opportunity no one else can. Together, we push the boundaries of known science and find new ways to connect and protect our world.
Raytheon brings the strength of more than 100 years of experience and renowned engineering expertise to meet the needs of today’s mission and stay ahead of tomorrow’s threat. We deliver solutions that help our nation and allies defend freedoms, and deter aggression, creating a safer, more secure world. Join us and help shape the future of aerospace and defense.

As a Principal System Safety Engineer, you will be accountable for the establishment and execution of the major safety programs.  The Safety Lead is a technical expert in missile safety as well as a project manager who establishes and monitors safety program execution, leads program safety teams, and interfaces with program & functional leadership.  This requires advanced application of MIL-STD 882E for System Safety (hardware, software, firmware, and personnel) for DoD Missile systems, typically obtained through advanced education combined with experience as well as project management experience and leadership.  Location: Huntsville, AL

What You Will Do

This is an exciting opportunity for a highly motivated Principal System Safety Engineer to join us onsite in Huntsville, AL, as a Safety Lead with proven experience in executing all aspects of system safety.

  • Practical application of project management skills: 
    • Create/update the strategy for the program to meet all its milestones with system safety features integrated into the product in compliance with contract and awarded funding.  
    • Create a schedule and integrate safety tasks and activities into program Integrated Master Schedule (IMS). 
    • Plan/manage the safety program effort within the Program IMS. 
    • Understanding of the safety budget and tasking through close coordination with the responsible CAM / IPTL / product owner, including EACs. 
    • Mentor junior safety engineers.    
    • Remove barriers impacting team members. 
  • Actively engage in engineering review boards, and configuration control boards to stay on top of design changes, and assess impacts to the established safety program.  
  • Establish on-going feedback loop with functional and program management.  
  • Lead & coordinate System Safety Working Group(s) between key Raytheon and Customer representatives.
  •  Escalate risks to the appropriate level and follow through on corrective actions.  
  • Interpret system requirements, customer specifications and military standards, so as to recommend compliance strategies to program leadership: Chief Engineer, Program Manager, Integrated Product Team Lead, etc. 
  • Collaborate with stakeholders across a range of engineering functions to identify and mitigate risks: Systems Engineering, Software Engineering, Firmware Engineering, Electrical Engineering, Hardware Engineering, Environmental Safety, & Health, Human Systems Interfaces, Test Engineering.  
  • Manage safety related interactions with suppliers and/or subcontractors.   
  • Innovate better safety solutions.  
  • Identify best practices to improve overall safety culture at Raytheon.  
  • Understand and shape system safety/Human System Interfaces postures across the lifecycle (design, integration/ test, flight test, production, field, returns). 

Qualifications You Must Have

  • Typically requires a degree in Science, Technology, Engineering or Mathematics (STEM) and a minimum of 8 years of prior relevant experience.
  • Experience developing and implementing MIL-STD-882E System Safety Program tasks and analyses, involving management (task series 100), analysis (task series 200), evaluation (task series 300), and verification (task series 400).  This includes hardware and software safety related tasks. 
  • Experience with presentation skills to brief safety status to safety approval authority at technical reviews, safety review boards, and others as part of the safety approval process.  
  • Experience managing a safety program.
  • Experience collaborating with stakeholders across a range of engineering functions to identify and mitigate risks.
  • The ability to obtain and maintain a Secret U.S. government issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for the required security clearance.

Qualifications We Prefer

  • An active and transferable Secret U.S. government issued security clearance.
  • Experience with briefing at the military safety review board.

What We Offer

Our values drive our actions, behaviors, and performance with a vision for a safer, more connected world. At RTX we value: Trust, Respect, Accountability, Collaboration, and Innovation.

Learn More & Apply Now!

  • Please consider the following role type definition as you apply for this role.
  • Onsite: Employees who are working in Onsite roles will work primarily onsite. This includes all production and maintenance employees, as they are essential to the development of our products.
  • This position requires the ability to obtain a security clearance. DCSA Consolidated Adjudication Services (DCSA CAS), an agency of the Department of Defense, handles and adjudicates the security clearance process. More information about Security Clearances can be found on the US Department of State government website here: https://www.state.gov/m/ds/clearances/c10978.htm 
  • Relocation Eligible

As part of our commitment to maintaining a secure hiring process, candidates may be asked to attend select steps of the interview process in-person at one of our office locations, regardless of whether the role is designated as on-site, hybrid or remote.

The salary range for this role is 107,500 USD - 204,500 USD. The salary range provided is a good faith estimate representative of all experience levels. RTX considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training, and key skills. Hired applicants may be eligible for benefits, including but not limited to, medical, dental, vision, life insurance, short-term disability, long-term disability, 401(k) match, flexible spending accounts, flexible work schedules, employee assistance program, Employee Scholar Program, parental leave, paid time off, and holidays. Specific benefits are dependent upon the specific business unit as well as whether or not the position is covered by a collective-bargaining agreement. Hired applicants may be eligible for annual short-term and/or long-term incentive compensation programs depending on the level of the position and whether or not it is covered by a collective-bargaining agreement. Payments under these annual programs are not guaranteed and are dependent upon a variety of factors including, but not limited to, individual performance, business unit performance, and/or the company’s performance. This role is a U.S.-based role. If the successful candidate resides in a U.S. territory, the appropriate pay structure and benefits will apply. RTX anticipates the application window closing approximately 40 days from the date the notice was posted. However, factors such as candidate flow and business necessity may require RTX to shorten or extend the application window.

RTX is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability or veteran status, or any other applicable state or federal protected class. RTX provides affirmative action in employment for qualified Individuals with a Disability and Protected Veterans in compliance with Section 503 of the Rehabilitation Act and the Vietnam Era Veterans’ Readjustment Assistance Act.

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About RTX

Sourced by ZipRecruiter

Industry

Guided missile and space vehicle manufacturing, it services, aerospace product and parts manufacturing and engineering professional services

Company size

10,000+ Employees

Headquarters location

Waltham, MA, US

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