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Senior Process Safety Engineer Jobs in Madison, WI

You will drive process performance through process development and design, data-driven ... Desire to grow toward a Senior Engineer role by leading complex cross-functional projects from ...

You will drive process performance through process development and design, data-driven ... Desire to grow toward a Senior Engineer role by leading complex cross-functional projects from ...

Process Engineer

Madison, WI ยท 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 ...

Process Engineer

Madison, WI ยท 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 ...

Process Engineer

Madison, WI ยท On-site

$70K - $85K/yr

Process EngineerWe're looking for a dependable Process Engineer who will be located in our Madison ... safety, quality, and continuous improvementWhat You'll DoDevise and execute plans to qualify new ...

Performance Measures and Outcome s 1. Safety metrics 2. Scrap / Lbs processed 3. Extrusion change time and compliance Education/Certification Level Required Bachelor's Degree in related Engineering ...

Performance Measures and Outcome s 1. Safety metrics 2. Scrap / Lbs processed 3. Extrusion change time and compliance Education/Certification Level Required Bachelor's Degree in related Engineering ...

The Process Engineering team is made up of Process Engineers and Automation Engineers with varied ... to safety and housekeeping standards. 3. Ability to work in a production environment around ...

The Process Engineering team is made up of Process Engineers and Automation Engineers with varied ... to safety and housekeeping standards. 3. Ability to work in a production environment around ...

Showing results 21-40

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 Aug 19, 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 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 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:

Nuclear Safety Analysis Engineer

SHINE Technologies LLC

Janesville, WI โ€ข Hybrid

$80K - $159K/yr

Full-time

Re-posted yesterday


Job description

Description

SHINE Technologies is seeking a Nuclear Safety Analysis Engineer to develop and apply nuclear safety analysis methodologies for safe and effective operations of the subcritical fission processes and accelerator technology for the production of medical isotopes. This work includes transient and accident analysis, dose analysis, process hazard analysis (HAZOPs, FMEAs, etc.), and integrated safety analysis. ย 


Hybrid work arrangement will be considered. Our headquarters is located in Janesville, Wisconsin; we welcome applicants from nearby areas who can effectively collaborate in a virtual environment and be on site at least 2 days a week. Candidates may be asked to travel occasionally for team meetings or onsite engagements, depending on business needs. ย 


The base salary range for this position is $80,500 - $159,275 per year plus a comprehensive compensation package. Our salary ranges are determined by role, level, and location.


Duties and Responsibilities:

Specific duties and responsibilities include, but are not limited to:

  • Perform system analyses of anticipated transients and postulated accidents to demonstrate that safety and licensing requirements are satisfied
  • Perform nuclear calculations to determine total amount of material at risk as input into release calculations using industry-standard codes such as MCNP and SCALE
  • Perform radiological and chemical dose calculations for normal and accidental releases
  • Support Integrated Safety Analysis (ISA) activities including hazard evaluations (e.g., HAZOP, FMEA), process hazard analyses (PHA), and accident sequence development
  • Review Quality Classification Forms that determine whether equipment is credited in the safety analysis
  • Maintain ownership of safety analysis documentation including dose release calculations, HAZOP and FMEA reports, and ISA Summary
  • Perform hand calculations using first principles to support and validate analysis results
  • Perform code benchmarking and validation analyses to support code qualification and methodology development
  • Contribute to licensing documents for NRC review and approval that describe how the suite of nuclear analysis codes will be applied along with inputs, models, and correlations to establish the design basesย 


Requirements

  • B.S. degree in Nuclear Engineering or related discipline from an accredited institutionย 
  • Five (5) years of experience in nuclear safety analysis; relevant graduate research or academic experience may be counted toward this requirement
  • Demonstrated technical writing skills
  • Knowledge of 10 CFR 70 integrated safety analysis requirements
  • Strong problem-solving and analytical skills

Preferences:ย 

  • Experience developing radioactive dose calculations including five-factor formula, source term development, and radioactive material transport, including use of standards and guides such as FGR 11 and 12 and DOE-HDBK-3010
  • Experience using MCNP and/or SCALE nuclear analysis codes
  • Previous training in performing or facilitating process hazards analysis (PHA), including HAZOP or FMEA

Eligibility for employment is conditioned on the applicant's ability to qualify for access to information subject to U.S. Export Controls. Additionally, applicant's eligibility may be conditioned based upon meeting the Nuclear Regulatory Commission requirements for access to Safeguards Information, which typically requires a pre-employment drug screen, fingerprinting and criminal background check.

SHINE values diversity in all its forms as a critical component of innovation, which is fundamental to our success. Every member of the SHINE community benefits from the talents and experiences of our peers, from the mutual respect we exercise, and from the responsibility we take for our actions.

SHINE Technologies 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, disability or veteran status.


Pay Transparency Policy

Employee Rights Under the NLRAย 

Equal Opportunity Employment

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