Principal Process Safety Engineer

Major Responsibilities

• Revise, develop and maintain Process Safety and Risk Management guidelines, procedures and standards to reflect current regulatory requirements and best practices.
• Develop and deliver training as necessary.
• Perform, facilitate and document process safety reviews (PHAs, HAZOPs, and MOCs) for revalidations and capital projects at Covestro's Newark Compounding Facility, ensuring all findings are tracked to closure.
• Lead and direct process hazard analyses utilizing HAZOP, What-If and Checklist methodologies; document all findings and action items.
• Advise project management and site leadership on regulatory impacts and provide specialized technical guidance on process safety issues; identify and initiate MOCs when changes to process, equipment or procedures warrant review.
• Ensure all PSM and Emergency Response System (ERS) programs meet local and global directed completion schedules; proactively manage resources and escalate risks to schedule as needed.
• Lead and participate in incident and near-miss investigations using structured Root Cause Analysis methodologies; develop and communicate corrective and preventive actions to prevent recurrence.
• Represent Newark Compounding on regional and global Covestro workgroups, contributing to the development of enterprise-wide standards and consistency throughout the organization.
• Support and advance department goals aligned with Process Safety and Corporate HSEQ objectives, contributing to a culture of continuous improvement.
• Lead and participate in safety-related capital projects, providing technical oversight in machinery safety, process safety and pressure safety from design through commissioning, including review of engineering designs, PSSRs and contractor safety compliance.
• Ensure key process safety related aspects such as dust explosion and pressure safety risks are accounted for and properly addressed throughout operations and capital project planning.

Basic Qualifications

• Bachelor's degree (BS) in Chemical Engineering, Process Engineering or equivalent engineering degree with a minimum of six (6) years of experience in process safety within the chemical or petroleum industries,
• or Master's degree (MS) in Chemical Engineering, Process Engineering or equivalent engineering degree with a minimum of four (4) years of experience in process safety within the chemical or petroleum industries.

Knowledge And Skills

• Demonstrated knowledge of OSHA PSM (29 CFR 1910.119), EPA RMP, and applicable local, state and insurance regulations governing chemical facility operations.
• Demonstrated ability to read, comprehend and apply P&IDs, material balances, equipment and layout drawings, and specifications for complex chemical processes.
• Proven experience performing, facilitating and documenting process hazard analyses using structured methodologies including HAZOP, What-If and Checklist approaches.
• Working knowledge of hazard identification, risk assessment and risk mitigation strategies including Layer of Protection Analysis (LOPA).
• Familiarity with Safety Instrumented Systems (SIS) and functional safety standards (IEC 61511/ISA 84).
• Strong analytical and problem-solving skills with the ability to apply technical principles and engineering judgment to complex process safety challenges.