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Senior Process Safety Engineer Jobs (NOW HIRING)

Buckman

Process Safety Engineer

Cadet, MO · On-site

$110K - $125K/yr

Process Safety Engineer Location: Cadet, MO, USA Language: English Travel: 10% - 15% Seniority Level: Associate Buckman is a privately held, global specialty chemical company with headquarters in ...

Ashland

Process Safety Engineer

Hopewell, VA · On-site

Process Safety Engineer Are you the kind of person who is always thinking, sketching, seeking, and adjusting? Who needs to understand how things work and then figure out how they can work better? Are ...

Ashland

Process Safety Engineer

Hopewell, VA

Process Safety Engineer Are you the kind of person who is always thinking, sketching, seeking, and adjusting? Who needs to understand how things work and then figure out how they can work better? Are ...

Ashland

Process Safety Engineer

Hopewell, VA · On-site

Process Safety Engineer Are you the kind of person who is always thinking, sketching, seeking, and adjusting? Who needs to understand how things work and then figure out how they can work better? Are ...

Mosaic Personnel

AR · On-site

$100K/yr

Process Safety Engineer Location : El Dorado, AR | Type : Full-Time | Industry : Chemical Manufacturing Target Salary: $100K + depending on experience Why This Opportunity Stands Out * Be the go-to ...

Vulcan Elements

Process Safety Engineer

Raleigh, NC · On-site

As a Process Safety Engineer you will be responsible for developing, implementing, and maintaining the organization's Process Safety Management (PSM) programs to ensure safe, compliant, and reliable ...

Vulcan Elements

Process Safety Engineer

Durham, NC · On-site

As a Process Safety Engineer you will be responsible for developing, implementing, and maintaining the organization's Process Safety Management (PSM) programs to ensure safe, compliant, and reliable ...

Vulcan Elements

Process Safety Engineer

Benson, NC · On-site

As a Process Safety Engineer you will be responsible for developing, implementing, and maintaining the organization's Process Safety Management (PSM) programs to ensure safe, compliant, and reliable ...

Targa Resources

Process Safety Engineer

Tulsa, OK · On-site

We encourage your interest in joining our team and pursuing the many opportunities we have at Targa Targa is seeking a Process Safety Engineer to lead the development and integration of corporate ...

ExxonMobil

Process Safety Engineer

Baton Rouge, LA

What role you will play in our team Process Safety Engineer who will advise operations in the management of process safety risks and hazards through technical support and facilitation of hazard ...

Danaher

Process Safety Engineer

Muskegon, MI

The Process Safety Engineer is responsible for working with our expert EHS team to support the multiyear construction, startup activities and then the ongoing plant operations for this world class ...

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Senior Process Safety Engineer information

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$75K

$121.1K

$170.5K

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

As of Jun 4, 2026, the average yearly pay for senior process safety engineer in the United States is $121,116.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,000.00 and $134,500.00 per year, depending on experience, location, and employer.

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 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 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.

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Senior Process Safety Engineer jobs near you
Infographic showing various Senior Process Safety Engineer job openings in the United States as of May 2026, with employment types broken down into 3% As Needed, 88% Full Time, 1% Part Time, and 8% Contract. Highlights an 99% Physical, and 1% Remote job distribution, with an average salary of $121,116 per year, or $58.2 per hour.
Process Safety Engineer

Process Safety Engineer

Fervo Energy Company

Houston, TX • On-site

Full-time

Posted 27 days ago

Job description

Job Type
Full-time
Description
Geothermal today is less than half a percent of the global electricity mix. This is not because the resource isn't there. It is, nearly everywhere. It's because no one has figured out how to build geothermal power plants cheaply and repeatedly enough to compete. Fervo is changing that. We have built the world's first commercial-scale enhanced geothermal system, and we will never build a first-of-a-kind project again. Everything from here is a product, not a project. The opportunity now is aggressive deployment to keep up with explosive demand to make geothermal an essential part of the global energy mix instead of a niche one.
Safety at Fervo is is a first-principles engineering challenge. We maintain world class process safety standards through the same continuous improvement mindset we apply to cost and schedule. We want a process safety engineer who understands that the best safety outcomes come from deeply understanding the design, not from adding layers of protection on top of a system nobody fully owns. If you want to build the safety foundation for a geothermal fleet and have your work matter at scale, this is the role.
As Process Safety Engineer on the Integration team, you own the process safety engineering scope across Fervo's ORC facility portfolio. That means hazard identification, consequence analysis, SIS design and validation, relief and blowdown system design, and the safety documentation that ties the plant together, from HAZOP through SIL assessment through startup. You sit on the integration team, which means you see across every engineering scope and are positioned to catch the risks that live at the boundaries between systems. You report to the Integration Lead.
Requirements
Responsibilities
Own Process Safety Across the Plant
  • Lead and own HAZOP, LOPA, and SIL assessment processes across the powerblock.
  • Own relief system design and validation of PSVs, rupture disks, flare and vent systems. Understand the full consequence basis, not just the set pressure.
  • Own the safety instrumented system (SIS) design and validation for the plant, including SIL verification, logic solver specification, and functional safety documentation in accordance with IEC 61511.
  • Question every inherited safety requirement. Trace every protection layer to its consequence basis. If it can't be justified by a credible hazard scenario, it should not be in the design.

Own the Integration Interface
  • Sit at the intersection of all engineering scopes and catch the process safety risks that live at system boundaries - between the ORC and utilities, between the turbine package and site infrastructure, between plant control and safety systems.
  • Define and maintain the safety-critical interface register for the plant. Every boundary between scopes that has a safety implication should be documented, owned, and tracked.
  • Own safety documentation - cause and effect matrices, functional descriptions, safety requirements specifications - and ensure they are updated as the design evolves, not treated as one-time deliverables.
  • Work closely with the controls team on the SIS/DCS interface. Safety logic and process control logic are separate systems with a well-defined boundary. Own your side of it.

Build the Standard
  • Standardize the process safety design basis, HAZOP methodology, and SIS architecture across all power plants. Every plant Fervo builds should benefit from the risk analysis done on the last one.
  • Drive safety engineering into the design process early, not late. The cheapest protection layer is the one that gets designed out of the hazard scenario before the P&ID is issued for construction.
  • Close the feedback loop between safety design and field operations aggressively. Incidents and near-misses are data. Apply them forward.

Qualifications
Required
  • B.S. or M.S. in Chemical, Mechanical, or Process Engineering or related discipline.
  • 7+ years of process safety engineering experience with direct ownership of HAZOP facilitation, LOPA, SIL assessment, and relief system design for power generation or industrial facilities.
  • Hands-on experience with IEC 61511 functional safety lifecycle, SIS design, and SIL verification. Strong understanding of consequence modeling, relief system design, and pressure protection philosophy.
  • Able to translate technical complexity into clear, fast decisions for cross-functional partners and project leadership.

Preferred
  • Background building something that had to scale, where the safety standard you set mattered beyond the project in front of you.
  • Experience with ORC, geothermal, or similar power generation process systems.
  • Certified Functional Safety Expert (CFSE) or equivalent.
  • Track record driving process safety standardization across multiple facilities or project phases.

Location
Fervo Energy is headquartered in Houston, TX with growing offices in Oakland, CA, Golden, CO, Reno, NV, and Salt Lake City, UT. This position will be eligible for some hybrid work flexibility, but regular in-office presence at Fervo's Houston office will be required. Some travel is required for this position.

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