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Become A Process Safety Engineer

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Working As A Process Safety Engineer

  • Evaluating Information to Determine Compliance with Standards
  • Getting Information
  • Communicating with Supervisors, Peers, or Subordinates
  • Updating and Using Relevant Knowledge
  • Making Decisions and Solving Problems
  • $94,500

    Average Salary

What Does A Process Safety Engineer Do

Health and safety engineers develop procedures and design systems to prevent people from getting sick or injured and to keep property from being damaged. They combine knowledge of systems engineering and of health or safety to make sure that chemicals, machinery, software, furniture, and other consumer products will not cause harm to people or damage to buildings.


Health and safety engineers typically do the following:

  • Review plans and specifications for new machinery and equipment to make sure they meet safety requirements
  • Identify and correct potential hazards by inspecting facilities, machinery, and safety equipment
  • Evaluate the effectiveness of various industrial control mechanisms
  • Ensure that buildings or products comply with health and safety regulations, especially after an inspection that required changes
  • Install safety devices on machinery or direct the installation of these devices
  • Review employee safety programs and recommend improvements
  • Maintain and apply knowledge of current policies, regulations, and industrial processes

Health and safety engineers also investigate industrial accidents, injuries, or occupational diseases to determine their causes and to determine whether the incidents could have been or can be prevented in the future. They interview employers and employees to learn about work environments and incidents that lead to accidents or injuries. They also evaluate the corrections that were made to remedy violations found during health inspections.

Health and safety engineers are also active in two related fields: industrial hygiene and occupational hygiene. In industrial hygiene, they focus on the effects of chemical, physical, and biological agents. They recognize, evaluate, and control these agents to keep people from becoming sick or injured. For example, they might anticipate that a particular manufacturing process will give off a potentially harmful chemical and recommend either a change to the process or a way to contain and control the chemical.

In occupational hygiene, health and safety engineers investigate the environment in which people work, and then use science and engineering to recommend changes to keep workers from being exposed to sickness or injuries. They help employers and employees understand risks, and improve working conditions and practices. For example, they might observe that the noise level in a factory is likely to cause harm to workers’ hearing and recommend ways to reduce the noise level through changes to the building or reducing exposure time, or by having workers wear proper hearing protection.

Health and safety engineering is a broad field covering many activities. The following are examples of types of health and safety engineers:

Aerospace safety engineers work on missiles, radars, and satellites to make sure that they function safely as designed.

Fire prevention and protection engineers design fire prevention systems for all kinds of buildings. They often work for architects during the design phase of new buildings or renovations. They must be licensed and must keep up with changes in fire codes and regulations.

Product safety engineers investigate the causes of accidents or injuries that might have resulted from the use or misuse of a product. They create solutions that reduce or eliminate safety issues associated with products. They also help design new products to prevent injuries, illnesses, or property damage.

Systems safety engineers work in many fields, including aerospace, and are moving into new fields, such as software safety, medical safety, and environmental safety. These engineers take a systemic approach to identify hazards so that accidents and injuries can be avoided.

For information on health and safety engineers who work in mines, see the profile on mining and geological engineers.

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How To Become A Process Safety Engineer

Health and safety engineers must have a bachelor’s degree, typically in an engineering discipline such as electrical, chemical, mechanical, industrial, or systems engineering. Another acceptable field of study is occupational or industrial hygiene. Employers value practical experience, so cooperative-education engineering programs at universities are valuable as well.


High school students interested in becoming health and safety engineers will benefit from taking high school courses in math and science, such as algebra, trigonometry, calculus, biology, chemistry, and physics.

Entry-level jobs as a health and safety engineer require a bachelor’s degree. Bachelor’s degree programs typically are 4-year programs and include classroom, laboratory, and field studies in applied engineering. Students interested in becoming a health and safety engineer should seek out coursework in occupational safety and health, industrial hygiene, ergonomics, or environmental safety. In addition, programs in mechanical, electrical, and industrial engineering, programs in systems engineering and fire protection engineering constitute good preparation for this occupation. ABET accredits programs in engineering.

Students interested in entering the relatively new field of software safety engineering may pursue a degree in computer science.

Many colleges and universities offer cooperative-education programs, which allow students to gain practical experience while completing their education.

A few colleges and universities offer 5-year accelerated programs through which students graduate with both a bachelor’s and a master’s degree. A master’s degree allows engineers to enter the occupation at a higher level, where they can develop and implement safety systems.

Important Qualities

Creativity. Health and safety engineers produce designs showing potential problems and remedies for them. They must be creative to deal with situations unique to a project.

Critical-thinking skills. Health and safety engineers must be able to identify hazards to humans and property in the workplace or in the home before they cause material damage or become a health threat.

Observational skills. Health and safety engineers must observe and learn how operations function so that they can identify risks to people and property. This requires the ability to think in terms of overall processes within an organization. Health and safety engineers can then recommend systemic changes to minimize risks.

Problem-solving skills. In designing solutions for entire organizational operations, health and safety engineers must take into account processes from more than one system at the same time. In addition, they must try to anticipate a range of human reactions to the changes they recommend.

Reading skills. Health and safety engineers must be able to interpret federal and state regulations and their intent so that they can propose proper designs for specific work environments.

Licenses, Certifications, and Registrations

Licensure is not required for entry-level positions as a health and safety engineer. A Professional Engineering (PE) license, which allows for higher levels of leadership and independence, can be acquired later in one’s career. Licensed engineers are called professional engineers (PEs). A PE can oversee the work of other engineers, sign off on projects, and provide services directly to the public. State licensure generally requires

  • A degree from an ABET-accredited engineering program
  • A passing score on the Fundamentals of Engineering (FE) exam
  • Relevant work experience, typically at least 4 years
  • A passing score on the Professional Engineering (PE) exam

The initial FE exam can be taken after one earns a bachelor’s degree. Engineers who pass this exam are commonly called engineers in training (EITs) or engineer interns (EIs). After meeting work experience requirements, EITs and EIs can take the second exam, called the Principles and Practice of Engineering.

Only a few states require health and safety engineers to be licensed. Licensure is generally advised for those opting for a career in systems safety engineering. States requiring licensure usually require continuing education for engineers in order to keep their license. Most states recognize licensure from other states, if the licensing state’s requirements meet or exceed their own licensure requirements.

Health and safety engineers typically have professional certification. Certifications include the following:

  • The Board of Certified Safety Professionals offers the Certified Safety Professional (CSP) certification, the Occupational Health and Safety Technologist (OHST), and a new certification called the Associate Safety Professional (ASP)
  • The American Board of Industrial Hygiene awards a certification known as a Certified Industrial Hygienist (CIH)
  • The American Society of Safety Engineers offers a Certificate in Safety Management (CSM)
  • The International Council on Systems Engineering offers a program leading to a designation as a Certified Systems Engineering Professional (CSEP)

Certification is generally needed to advance into management positions.


New health and safety engineers usually work under the supervision of experienced engineers. To move to more difficult projects with greater independence, a graduate degree is generally required, such as a master’s degree in engineering or a Master of Public Health (MPH) degree.

An advanced degree allows an engineer to develop and implement safety programs. Certification as a safety professional or as an industrial hygienist is generally required for entry into management positions. For more information, see the profile on architectural and engineering managers.

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Process Safety Engineer jobs


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Process Safety Engineer Demographics












Hispanic or Latino




Black or African American

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Languages Spoken




















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Process Safety Engineer Education


University of Houston


Lamar University


North Carolina State University


University of Puerto Rico - Mayaguez


Columbia Southern University


Oklahoma State University


Louisiana Tech University


Drexel University


University of Massachusetts - Lowell


Texas A&M University


Syracuse University


University of Nevada - Reno


University of Alabama


Ohio University -


University of Florida


San Jose State University


West Virginia University Institute of Technology


University of California - Los Angeles


University of California - Davis


University of Illinois at Chicago

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Chemical Engineering




Mechanical Engineering




Occupational Safety And Health


Industrial Technology


Electrical Engineering


Environmental Engineering


Environmental Science


Fire Science And Protection


Environmental Control Technologies/Technicians




Petroleum Engineering


Engineering Technology


Public Health


Biochemistry, Biophysics, Molecular Biology








Construction Management

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Real Process Safety Engineer Salaries

Job Title Company Location Start Date Salary
Senior Process Safety Engineer Bechtel Oil, Gas &Amp; Chemicals, Inc. Houston, TX Oct 30, 2012 $237,792
Senior Process Safety Engineer Bechtel Oil, Gas &Amp; Chemicals, Inc. Houston, TX Nov 01, 2012 $237,792
Senior Process Safety Engineer Bechtel Oil, Gas & Chemicals, Inc. Houston, TX Nov 15, 2010 $217,986
Process Safety Bechtel Oil, Gas & Chemicals, Inc. Houston, TX Nov 15, 2010 $217,986
Process & Safety Engineer BP America Inc. Houston, TX Sep 17, 2012 $180,000
Senior Process Safety Engineer Broken Hill Proprietary (USA) Inc. Houston, TX Dec 30, 2015 $174,000 -
Process Safety Engineer BP America Inc. Houston, TX Sep 17, 2012 $170,000
Process Safety-Senior Engineer Bechtel Oil, Gas and Chemicals, Inc. Houston, TX Nov 12, 2015 $164,448
Process Safety-Senior Engineer Bechtel Oil, Gas & Chemicals, Inc. Houston, TX Jul 11, 2015 $160,140 -
Lead Process Safety Engineer Bechtel Oil, Gas &Amp; Chemicals, Inc. Houston, TX Sep 17, 2013 $153,650 -
Process Safety & Integrity Engineer Santos GLNG Corp Houston, TX Mar 26, 2012 $145,000 -
Process Safety Engineer BP America Inc. Naperville, IL Jun 10, 2015 $138,000
Process Safety Engineer BP America Inc. Naperville, IL May 01, 2013 $128,420
Process Safety Engineer BP America Inc. Naperville, IL Sep 30, 2015 $128,420 -
Lead Technical Process Safety Engineer Maersk Oil Houston, Inc. Houston, TX Apr 01, 2013 $104,083 -
Senior Process Fires Safety Engineer Bechtel Oil, Gas & Chemicals, Inc. Houston, TX May 17, 2013 $104,083 -
Lead Technical Process Safety Engineer Maersk Oil Houston, Inc. Houston, TX Aug 25, 2011 $103,667 -
Lead Process Safety Engineer Maersk Oil Houston, Inc. Houston, TX Dec 12, 2011 $103,667 -
Process Safety Engineer Smith & Burgess LLC Houston, TX Sep 02, 2015 $103,147
Senior Process Safety/Risk Engineer PSRG, Inc. Houston, TX Dec 15, 2016 $102,000
Principal Process Safety Engineer Air Products and Chemicals, Inc. Allentown, PA Sep 20, 2014 $102,000 -
Senior Process Safety Engineer Air Products and Chemicals, Inc. Allentown, PA Sep 01, 2013 $84,906 -
Process Safety Engineer Evonik Corporation Theodore, AL Feb 09, 2016 $84,900 -
Senior Process Safety Engineer Bayer Materialscience, LLC Baytown, TX Sep 24, 2012 $84,344
Senior Process Safety Engineer Bayer Business and Technology Services, LLC Baytown, TX Sep 24, 2012 $84,344
Associate Process Safety Engineer Worleyparsons Group, Inc. Bellaire, TX Nov 01, 2011 $82,000
Senior Process Safety Consultant/Engineer Siemens Energy, Inc. Houston, TX Aug 31, 2011 $80,392 -
Process & Pressure Safety Engineer Bayer Business and Technology Services, LLC Baytown, TX Aug 31, 2013 $80,000

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Top Skills for A Process Safety Engineer


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Top Process Safety Engineer Skills

  1. Osha Process Safety Management
  2. PHA
  3. Facility
You can check out examples of real life uses of top skills on resumes here:
  • Provided leadership and enforced compliance with OSHA Process Safety Management standards in conjunction with corporate standards.
  • Facilitated multiple Functional Hazard Risk Assessments (FHRA) and Process Hazard Analyses (PHA) for high risk manufacturing processes.
  • Conducted site and facility inspections and audits that identified and corrected 2 potentially severe process design issues.
  • Assist in the development of operating and maintenance procedures.
  • Provide emergency response coverage for the facility to accomplish full regulatory compliance for Process Safety Management.

Top Process Safety Engineer Employers