Senior Principal Design Safety Engineer

Job Description

Company Overview
BAE Systems, one of the world's leading defense contractors, is seeking a Senior Principal Design Safety Engineer to support explosive safety and Department of War (DOW) compliance at the Radford Army Ammunition Plant (RFAAP). BAE Systems manufactures chemicals, propellants, and other energetic materials, including explosives, at both the RFAAP and Holston Army Ammunition Plant (HSAAP) sites. This role will provide critical safety oversight at Radford and may provide remote support to HSAAP in Kingsport, TN, as required.

Role Overview
As a key member of the Hazards Analysis Team, the Principal Safety Professional/Engineer provides explosive and technical safety support across various manufacturing areas at RFAAP. Primary areas of focus include explosive decontamination processes, change approvals, tooling reviews, area inspections, technical safety reviews, and specialized energetic testing. Additionally, this role provides Site Safety Committee support, ensures DOW code compliance, responds to Army inquiries, and supports modernization projects on an as-needed basis.

Primary Duties and Responsibilities

• Hazard Mitigation: Develop and maintain a comprehensive working knowledge of common hazards associated with processing energetic materials and implement effective prevention and mitigation strategies.
• Compliance & Regulation: Develop a deep understanding of applicable DOW requirements for RFAAP manufacturing processes to ensure full regulatory compliance.
• Safety Planning: Support overall explosive safety compliance, including the development of Explosive Safety Site Plans and associated documentation.
• Waivers & Approvals: Manage and support the site waiver and explosive site safety plan processes.
• Technical Advisory: Provide expert technical safety guidance to manufacturing areas and management teams.
• Policy Development: Establish and maintain safety policies and standards for the Hazards Analysis group and related areas of expertise.
• Change Management: Support manufacturing process and equipment changes by conducting code compliance reviews, technical analyses, and area inspections.
• Project Lifecycle Support: Partner with project teams throughout the design, build, and commissioning phases, providing Design and Process Safety analysis to ensure safe and compliant operations.
• Risk Analysis: Participate in internal design reviews, root cause analyses, and Process Hazard Analysis (PHA) meetings.
• Action Tracking: Collaborate closely with project teams to ensure the timely completion of all PHA-generated follow-up actions.
• Investigations: Lead and perform safety investigations as required.

Required Education, Experience, & Skills

• Typically a Bachelor's Degree in engineering or safety and 8+ years related experience. Adequate applicable work experience will be accepted in place of a formal degree.
• Experience in required practices for safe operations involving hazardous chemicals such as flammable liquids and gases, reactive solids and liquids, toxic materials, corrosive materials, poisonous materials, explosives and other shock/friction sensitive materials, etc.
• Experience in design and/or evaluation of required practices for safely operating hazardous chemical processes.
• Experience in reading, interpreting, evaluating, and specifying compliance with a wide range of regulations and codes including, but not limited to OSHA, NFPA, and IBC.
• Experience in hazard identification and mitigation through leading, conducting, and/or participating in Process Hazard Analysis studies, root cause failure analysis, Job Hazard Analysis, and other risk analysis methods.
• Experience providing process and industrial safety support. Experience in a chemical manufacturing environment preferred.
• Experience in reading, interpreting, evaluating, and specifying compliance with regulations and codes including, but not limited to OSHA, NFPA, and IBC.
• Good communication and reasoning skills.
• Attention to detail.
• Ability to work effectively and constructively with others.
• This role requires regular presence in a manufacturing or fabrication environment. The incumbent must be able to access and safely navigate production areas which may include climbing, kneeling, stooping, and working in confined spaces. Must also be able to comply with all requirements including the use of required personal protective equipment (PPE) in accordance with company policy. Must be able to carry up to 50 pounds intermittently.
• We will consider candidates with fewer years experience for a more junior position or additional experience for a more senior position.

Preferred Education, Experience, & Skills

• Experience in safe design of facilities handling propellants and explosives.
• 12+ years relevant experience.
• Experience in performing qualitative and/or quantitative hazard analysis of impact, friction, static electricity, and shock hazards of propellants and explosives.
• Experience in supporting compliance with OSHA, NFPA, DOW, and other standards.
• Experience leading incident investigation utilizing root cause analysis techniques.
• CSP - Certified Safety Professional.

Pay Information
Full-Time Salary Range: $120874 - $205486

Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.

Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.


About BAE Systems Platforms & Services
BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, but it’s what we do at BAE Systems. Working here means using your passion and ingenuity where it counts – defending national security with breakthrough technology, superior products, and intelligence solutions. As you develop the latest technology and defend national security, you will continually hone your skills on a team—making a big impact on a global scale. At BAE Systems, you’ll find a rewarding career that truly makes a difference.

The Platforms & Services (P&S) sector under BAE Systems, Inc does the big stuff: the armored combat vehicles, naval guns, missile launchers, and naval ship repair…just to name a few. Our employees take pride in the work they do and why they do it. They are on the front lines every day, building our products to protect the lives of those who serve. We may be biased, but we think P&S does some of the coolest work around, and we think you will too.

This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.