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Senior Process Safety Engineer Jobs in Madison, WI

Merck Group

Process Safety Engineer

Verona, WI · On-site

$75K - $120K/yr

Bachelor's Degree in Chemical Engineering, Environmental Engineering or other Engineering discipline. * 2+ years' experience in implementing process safety programs. * 1+ year experience in ...

Amtec Corporation

SAFETY ENGINEER

Janesville, WI · On-site

Safety Engineer DEPARTMENT: Engineering REPORTS TO: Manufacturing Engineering Manager POSITION ... OSHA Process Safety Management standard, oversight/auditing, and leadership of incident ...

Shirley Parsons

Sr. EHS&R Manager [SM-15065]

Madison, WI · On-site

A growing manufacturing organization in the Waunakee, WI area is seeking a Senior EHS&R Manager to ... Partner cross-functionally with operations, engineering, and HR on process safety, MOC, and workers ...

Iff

Process Engineering Intern

Madison, WI

Quality, Safety, Food Safety, Environmental, GMPs, Dietary Supplements, and HACCP-HARPC * Adhere to ... Process Hazard Analysis and Process Safety Management exposure Job Requirements * Available to work ...

Sharpe Engineering

Process Engineer

Madison, WI · On-site

... safety, and operational excellence. In this role, you'll collaborate closely with clients, internal engineering teams, contractors, and vendors. You will play a key role in shaping process solutions ...

Sharpe Engineering

Process Engineer

Madison, WI · On-site

... safety, and operational excellence. In this role, you'll collaborate closely with clients, internal engineering teams, contractors, and vendors. You will play a key role in shaping process solutions ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

Process Engineer We're looking for a dependable Process Engineer who will be located in our Madison ... A culture focused on safety, quality, and continuous improvement What You'll Do * Devise and ...

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Senior Process Safety Engineer information

See Madison, WI salary details

$75.6K

$122.1K

$171.8K

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

As of Jul 27, 2026, the average yearly pay for senior process safety engineer in Madison, WI is $122,058.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 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 pharmaceutical 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?

Senior Process Safety Engineers can earn salaries exceeding $150,000 annually, especially with extensive experience, advanced certifications, and working in high-risk industries such as oil and gas or chemical manufacturing. Top earners in this field may reach salaries over $180,000 or more, depending on location and employer size.

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 includes bonuses, profit sharing, and other incentives for senior-level professionals managing complex safety systems and compliance.

What engineers make $200,000 a year?

Senior Process Safety Engineers can earn $200,000 or more annually, especially with extensive experience, specialized certifications, and working in high-demand industries like oil and gas or chemical manufacturing. Compensation varies based on location, company size, and individual expertise, often including bonuses and benefits.

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, WI? For Senior Process Safety Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Senior Process Safety Engineer jobs in Madison, WI look for? The top searched job categories for Senior Process Safety Engineer jobs in Madison, WI are:
Senior Process Safety Engineer jobs near you

Process Safety Engineer

The businesses of Merck KGaA, Darmstadt, Germany

Verona, WI • On-site

$75K - $120K/yr

Full-time

Medical, Retirement, PTO

Posted 13 days ago

Job description

Work Your Magic with us!Start your next chapter and join MilliporeSigma.

Ready to explore, break barriers, and discover more? We know you've got big plans - so do we! Our colleagues across the globe love innovating with science and technology to enrich people's lives with our solutions in Healthcare, Life Science, and Electronics. Together, we dream big and are passionate about caring for our rich mix of people, customers, patients, and planet. That's why we are always looking for curious minds that see themselves imagining the unimaginable with us.

This role does not offer sponsorship for work authorization. External applicants must be eligible to work in the US.


Your Role

In this role, you will be responsible for implementing process safety programs at your assigned site(s) based on regulation and corporate governance direction.

Responsibilities include but not limited to:

  • Develop compliance programs and site operating procedures for implementing process safety requirement.
  • Maintain lists of process safety related actions.
  • Prepare process safety deliverables for CapEx projects as outlined in corporate program.
  • Completion of Process Hazard Reviews using Hazard and Operability Study methodology and facilitating pre-start up safety review.
  • Facilitate Process Hazard Analysis.
  • Conduct or request consequence modeling.
  • Provide technical expertise in one or more of the following areas: risk assessment, chemical reactivity, fire protection systems and mechanical integrity.
  • Collaborate with Life Science Process Safety Center of Excellence; participating in Center of Excellence meetings, actively participating in Life Science Business Process Safety program development standards, tools, attend and lead trainings, lead site Process Safety initiatives developed by Center of Excellence.
  • Travel between the Madison and Verona Wisconsin sites.

Physical Attributes:

  • Wear appropriate Personal Protective Equipment including but not limited to goggles and gloves.

Who You Are

Minimum Qualifications:

  • Bachelor's Degree in Chemical Engineering, Environmental Engineering or other Engineering discipline.
  • 2+ years' experience in implementing process safety programs.
  • 1+ year experience in facilitating process hazard analyses.

Preferred Qualifications:

  • Experience with preparing and providing training on process safety topics.
  • Experience with quantitative consequence modeling.
  • Experience with leading Layer of Protection Analysis and Safety Integrity Level calculation.
  • Experience with regulatory auditing of process safety programs.
  • Experience with chemical reactivity assessments and knowledge of chemical processes and equipment.
  • Experience with Process Safety Management standardization.
  • Experience with applying process safety requirements at a project level.
  • Knowledge of the following chemical processes; bioprocessing, organic chemistry, inorganic chemistry, combustible dusts and other volatile solvents.

Pay Range for this position: $75,300 - $120,700 annually

The offer range represents the anticipated low and high end of the base pay compensation for this position. The actual compensation offered will be determined by factors such as location, level of experience, education, skills, and other job-related factors. Position may be eligible for sales or performance-based bonuses. Benefits offered by the Company include health insurance, paid time off (PTO), retirement contributions, and other perquisites. For more information clickhere.

RSREMD


What we offer: We are curious minds that come from a broad range of backgrounds, perspectives, and life experiences. We believe that this variety drives excellence and innovation, strengthening our ability to lead in science and technology. We are committed to creating access and opportunities for all to develop and grow at your own pace. Join us in building a culture of inclusion and belonging that impacts millions and empowers everyone to work their magic and champion human progress!

Apply now and become a part of a team that is dedicated to Sparking Discovery and Elevating Humanity!

Employment Type: FULL_TIME

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