Senior Safety Design Engineer

Senior Safety Design Engineer 

This senior-level role is central to Redwood’s mission of operational safety, responsible for leading and implementing robust process safety management practices across engineering, operations, and maintenance teams. The successful candidate will be a recognized expert in Process Hazard Analyses (PHAs), Task-Based Risk Assessments (TBRAs), and People Safety Risk Assessments (PSRAs). They will serve as a core technical resource to ensure the safe design, startup, and operation of chemical and mechanical processes across Redwood’s facilities. The bulk of this work will focus on reviewing designs for new equipment, conducting risk assessments on those designs, and providing critical feedback to the Process Engineering team to ensure conformance with Redwood’s internal safety and engineering standards. Standardization of process safety approaches, tools, and documentation across the organization is also a key component of this role. The position requires a strong foundation in process engineering with demonstrated ability to apply safety principles in complex, high-hazard environments. The candidate should bring strong leadership, communication, and facilitation skills, with the ability to influence and train cross-functional teams. 

Responsibilities Will Include:

• Lead and document Process Hazard Analyses (HAZOP, LOPA, What-If) for new and existing systems. 
• Perform Task-Based Risk Assessments (TBRAs) and People Safety Assessments (PSAs) in coordination with EHS and Operations. 
• Review equipment and system designs and provide safety-focused feedback to Process Engineering. 
• Support development and validation of safety instrumented systems (SIS) and risk mitigation controls. 
• Participate in incident investigations and root cause analyses for process safety events. 
• Work closely with engineers to evaluate thermal, pressure, and chemical hazards during design and operation. 
• Ensure compliance with relevant codes and standards (e.g., NFPA, API, NV’s CAPP, EPA RMP, OSHA PSM). 
• Support standardization of process safety procedures, equipment startup documentation, and assessment methodologies. 
• Train internal teams on hazard analysis methodologies and hazard recognition. 
• Contribute to the development and implementation of Redwood’s Process Safety Management (PSM) framework. 

Desired Qualifications:

• B.S. or higher in Chemical Engineering preferred. Mechanical / Industrial / Electrical Engineering or other Engineering focus is acceptable with significant relevant experience. 
• Fire Protection Engineers, with demonstrated process safety experience may also be considered. 
• 5–10+ years of relevant experience in industrial process & / or process safety engineering. Leveling (Associate, Senior, Staff, etc.) will be commensurate with experience.  
• Proven track record leading PHAs and conducting formal risk assessments. 
• Direct experience in a process engineering role required. 
• Experience in the battery, specialty chemical, or energy industry is a strong plus. 
• Expertise in PHA methodologies (HAZOP, LOPA, FMEA). 
• Familiarity with SIS design, functional safety (IEC 61511), and control system hazards. 
• Experience with relief systems, dispersion modeling, or consequence analysis is a plus. 
• Experience with conducting Dust Hazard Analyses (DHA) and Electrical Area Classifications (EAC) a strong plus. 
• Experience with machine & manufacturing safety a strong plus. 
• Proficient in PHA software tools (e.g., PHAPro) & modeling techniques (ALOHA, PHAST etc) 
• Competent in interpreting P&IDs, logic diagrams, and safety requirement specifications. 
• Strong facilitation, communication, and leadership skills. 
• Ability to influence across departments and work with executive stakeholders. 

Physical Requirements:

• Ability to perform job functions safely and effectively in accordance with all regulatory and company standards. Must be able to conduct site walkdowns, wear appropriate PPE including respiratory protection, and lift up to 30 lbs. Standing for extended periods may be required. 

Working Conditions:

• Primary work will be performed in an office setting with regular visits to process development and manufacturing areas. Some exposure to loud noise, extreme temperatures, and hazardous materials may occur. Occasional travel to other sites (2–4 times per year) is expected.