Senior Process Safety Engineer: Design, Risk & Compliance

TPC Group; Houston (TX); On-site; USD 120,000 - 170,000; Full time

Job summary

TPC Group is seeking a Sr. Engineer, Process (Process Safety Emphasis) to lead process safety design, hazard recognition, and GEMS updates across the pipeline of projects in Houston.

The role requires coordinating SIS, mechanical integrity, and operations to close PSM gaps and ensure safe, compliant operations. The successful candidate will bring a chemical engineering background, 10+ years in refinery or petrochemical environments, and proficiency with ASPEN+, HYSIS, and PROSIM.

Qualifications

• Bachelor’s degree in Chemical Engineering.
• 10+ years in chemical engineering with refinery/petrochemical experience.
• Experience with process safety and unit operation simulation.
• Strong communication and leadership across cross-functional teams.
• Familiarity with ASPEN+, HYSIS, and PROSIM.
• Ability to manage ambiguity.

Responsibilities

• Provide technical authority for process safety technologies across all processes.
• Develop unit production expertise and technical knowledge.
• Lead inherent process safety in design concepts and update GEMS.
• Develop high level scopes for unit improvements and PSM gaps.
• Provide leadership to operations, R&D, and Corporate Development for new projects.
• Support PSM programs via PHA, LOPA, MOC, RCA and action items.
• Lead cross-functional teams in evaluating process safety issues.
• Develop designs’ feasibility and safety and propose engineering solutions.
• Lead FEED and scoping for projects and transitions to startup; SOP development.

Skills

Communication skills

Leadership

Cross-functional collaboration

Education

Bachelor’s Degree in Chemical Engineering

Tools

ASPEN+

HYSIS

PROSIM

Job description

TPC Group is seeking a Sr. Engineer, Process (Process Safety Emphasis) to lead process safety design, hazard recognition, and GEMS updates across the pipeline of projects in Houston.

The role requires coordinating SIS, mechanical integrity, and operations to close PSM gaps and ensure safe, compliant operations. The successful candidate will bring a chemical engineering background, 10+ years in refinery or petrochemical environments, and proficiency with ASPEN+, HYSIS, and PROSIM.