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 and document process safety reviews (PHAs, HAZOPs, MOCs, and PSSRs) for revalidations and capital projects at Covestro's Newark Compounding Facility, ensuring all findings are tracked to closure.
• Support project management and site leadership by identifying regulatory impacts and contributing technical input on process safety issues; assist in identifying when MOCs are required for changes to process, equipment or procedures.
• Support efforts to ensure all PSM and Emergency Response System (ERS) programs meet local and global directed completion schedules; assist in identifying and escalating risks to schedule as needed.
• Conduct incident and near-miss investigations using structured Root Cause Analysis methodologies; develop and communicate corrective and preventive actions to prevent recurrence.
• Support Newark Compounding's participation in regional and global Covestro workgroups, contributing to the development of enterprise-wide standards and consistency throughout the organization.
• Work alongside the Local Machinery Safety Expert to help ensure corporate machinery safety requirements for facility operations and capital projects.
• Support the HSEQ team on safety-related capital projects, contributing technical input in machinery safety, process safety and pressure safety from design through commissioning, including review of engineering designs, PSSRs and contractor safety compliance.
• Affirmatively ensure key process safety related aspects such as dust explosion and pressure safety risks are identified 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 three (3) 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 two (2) years of experience in process safety within the chemical or petroleum industries.

Knowledge And Skills

• Foundational knowledge of OSHA PSM (29 CFR 1910.119), EPA RMP, and applicable local, state and insurance regulations governing chemical facility operations.
• Ability to read, comprehend and apply P&IDs, material balances, equipment and layout drawings, and specifications for chemical processes.
• Developing experience performing and documenting process hazard analyses using structured methodologies such as HAZOP, What-If and Checklist approaches.
• Basic understanding of hazard identification, risk assessment and risk mitigation strategies; familiarity with Layer of Protection Analysis (LOPA) concepts.
• Awareness of 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.