Sr. PSM Engineer

Position Summary

The Senior Process Safety Management (PSM) Engineer serves as a technical leader responsible for the implementation, continuous improvement, and governance of Process Safety Management programs across a large chemical manufacturing facility. This role partners closely with Operations, Maintenance, Process Design, Technical Services, Health & Safety, Environmental, and plant leadership to ensure compliance with OSHA PSM, EPA Risk Management Program (RMP), and company process safety requirements while driving a strong process safety culture. Reporting into the Site Process Safety Leader, the position provides technical leadership for risk identification, hazard analysis, incident investigations, management of change, and safeguard effectiveness programs.

Key Responsibilities

Process Safety Leadership

Lead and facilitate Process Hazard Analyses (PHAs), Human Factors and Facility Siting assessments, and Layers of Protection Analyses (LOPAs) for global process revalidations, MOCs, Projects, and Incidents

Serve as a site subject matter expert for one or more PSM elements

Drive continuous improvement of process safety programs and risk management practices

Partner with site leadership to strengthen process safety culture and competency across the organization

Mentor engineers, operations personnel, and cross-functional teams on process safety principles

Regulatory Compliance

Ensure compliance with OSHA Process Safety Management (29 CFR 1910.119), EPA Risk Management Program requirements, and applicable corporate standards

Support process safety audits and regulatory inspections

Lead closure of audit findings, recommendations, and compliance actions.

Support development and maintenance of process safety procedures, standards, and training programs

Risk Management and Hazard Analysis

Evaluate process hazards and recommend effective layers of protection and risk reduction measures

Assess the effectiveness of engineered, administrative, and procedural safeguards

Conduct consequence analyses and release modeling

Management of Change (MOC)

Provide technical leadership and governance for Management of Change activities

Review proposed process modifications for process safety impacts and regulatory compliance

Ensure hazards are appropriately identified, evaluated, documented, and mitigated before implementation

Verify completion of pre-startup safety reviews and required documentation updates

Incident Investigation and Learning

Lead and facilitate investigations of process safety incidents and near misses

Apply root cause analysis methodologies to identify systemic causes and corrective actions

Track corrective actions through completion and verify effectiveness

Share lessons learned across site and corporate networks

Mechanical Integrity and Safeguard Management

Support Mechanical Integrity programs for critical process equipment

Assist reliability and maintenance teams in the management of process safety-related equipment

Verify process safety safeguards are functioning as intended and continue to provide the required protection

Required Qualifications

Bachelor's degree in Chemical Engineering, Mechanical Engineering, or related engineering discipline

Minimum 5 years of chemical manufacturing or industrial process experience

Experience with incident investigation and root cause analysis methods

Experience with risk assessment methodologies

Experience working in an OSHA PSM and/or EPA RMP regulated environment

Excellent communication, leadership, and project management skills

Preferred Qualifications

Demonstrated experience leading Process Hazard Analyses

Strong working knowledge of OSHA PSM and EPA RMP regulations

3 years of Process Safety Management experience

Six Sigma certification or equivalent continuous improvement training

Experience with consequence modeling

Mechanical Integrity program experience

Base salary range for this position is $95,000 to $142,600 annually.