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Senior Process Safety Engineer Jobs (NOW HIRING)

ERG

Senior Process Safety/Chemical Engineer

Raleigh, NC · Remote

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

ERG

Senior Process Safety/Chemical Engineer

Fairfax, VA · On-site +1

$110K - $155K/yr

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

ERG

Senior Process Safety/Chemical Engineer

Fairfax, VA · On-site

$110K - $155K/yr

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

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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 25, 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 engineers make $300,000 a year?

Senior Process Safety Engineers in the chemical, oil and gas, or petrochemical 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?

The highest salary for a senior process safety engineer can exceed $150,000 annually, especially with extensive experience, advanced certifications, and working in high-demand industries such as oil and gas or chemical manufacturing. Top earners often have specialized skills in risk assessment, process hazard analysis, and safety management systems.

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 reflects the critical safety responsibilities, technical expertise, and the complexity of the facilities they oversee.

How much do process safety engineers make in the US?

Process safety engineers in the US typically earn a median annual salary of around $90,000 to $110,000, with experienced professionals and those in senior roles earning over $130,000. Salaries vary based on location, industry, certifications, and years of experience, and the role often requires knowledge of safety standards and risk management tools.

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.
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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 June 2026, with employment types broken down into 79% Full Time, and 21% Contract. Highlights an 95% In-person, and 5% Remote job distribution, with an average salary of $121,116 per year, or $58.2 per hour.
Senior Process Safety/Chemical Engineer

Senior Process Safety/Chemical Engineer

ERG

Raleigh, NC • Remote

Full-time

Posted 6 days ago

Job description

ERG is a research and consulting firm that provides a wide range of support to federal, state, and commercial clients. ERG offers multidisciplinary teams with nationally recognized skills in engineering, science, economics, public health, informational technology, and communications. We hire people with the best minds and then provide them with a vibrant and flexible environment in which to develop their careers. The qualified individual must be highly motivated with the skills to prioritize, perform, and communicate effectively in a fast-paced environment.

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to our local, State, and Federal clients. The ideal candidate will be responsible for leading technical engineering and compliance investigations in relation to Section 112(r) of the Clean Air Act (both the General Duty Clause and RMP), as well as applicable Emergency Preparedness and Community Right-to-Know Act (EPCRA) and Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) requirements. The Senior Process Safety Engineer or Chemical Engineer would help to expand our growing team in this area both in areas of expertise and client base.
Job Description:
  • Direct medium to large scale complex projects to ensure internal and external expectations are met for scope, budget, schedule and quality
  • Review and interpret technical engineering documentation, including but not limited to: offsite consequence analyses (OCAs), process safety information; process hazard analyses (PHAs); operating procedures; training records; mechanical integrity programmatic records; management of change (MOC) and pre-startup safety review (PSSR) packages; compliance audits; incident investigations; employee participation plans; hot work permits; contractor management plans; and emergency response programs and procedures
  • Lead and support on-site compliance evaluations and inspections
  • Engage comfortable with personnel at facilities in the following industry types: petroleum refineries, chemicals manufacturing facilities, anhydrous ammonia refrigeration facilities, flammable storage facilities, natural gas processing plants, and chemical storage warehouses
  • Manage and train junior and mid-level staff to facilitate growth
  • Collaborate and communicate effectively with multiple clients and internal stakeholders regarding project progress and budget status
  • Occasional travel to investigation sites (up to 25%)
Qualifications and Skills:
  • 10-15 years of experience in process safety and/or chemical engineering
  • EPA RMP, OSHA PSM, and/or similar state-level program compliance experience
  • Proven project manager with ability to manage multiple projects and subcontractors on time and on budget
  • Ability to prioritize, perform, and communicate effectively in a fast-paced environment
  • Be able to carry 25 pounds, climb ladders, and work on elevated platforms
ERG is an equal opportunity employer and complies with all applicable EEOC regulations. All qualified applicants will receive consideration for employment without regard to age, race, color, religion, sex, sexual preference, national origin, disability, or status as a protected veteran.  

Please be aware, the only authentic corporate domain for ERG is https://www.erg.com.  ERG may, on occasion, screen applicants via telephone or video interviews via Skype, Teams, GoToMeeting, or another type of video platform. However, any candidate extended a job offer might be asked to meet in person with an ERG employee before providing confidential personal information associated with new employment. 

If you’re a qualified individual with a disability or a disabled veteran, you have the right to request a reasonable accommodation if you are unable or limited in your ability to use or access ERG’s online application process as a result of your disability. To request accommodation, please contact Human Resources via email at Resumes-Lex@erg.com or call (781) 674-7293. 

ERG fosters a friendly, flexible work environment. ERGers are dedicated to serving clients who are committed to making the world a better place. We promote and recognize principles of fairness and respect in the work we do, the partnerships we foster, and the culture we value both within and outside of our organization.