HSE Engineer III - Process Safety Management

Responsibilities

• Lead development, implementation, and continuous improvement of enterprise-wide HSE and Process Safety Management (PSM) programs supporting propulsion testing, hazardous operations, and launch activities.
• Serve as the senior HSE and PSM subject matter expert for high-risk aerospace operations involving propellants, cryogenics, pressure systems, hazardous chemicals, and energized systems.
• Manage and maintain OSHA Process Safety Management (29 CFR 1910.119) program elements for applicable highly hazardous chemical processes and operations.
• Facilitate and participate in Process Hazard Analyses (PHA), What-If analyses, HAZOPs, Layer of Protection Analysis (LOPA), and other formal risk assessments for hazardous systems and operations.
• Partner with engineering and operations teams to ensure process safety considerations are incorporated into system design, modifications, Management of Change (MOC), and operational readiness activities.
• Lead incident investigations, root cause analyses, corrective action development, and lessons learned implementation for safety, environmental, operational, and process safety events.
• Develop and maintain PSM documentation including operating procedures, safe work practices, process safety information (PSI), mechanical integrity records, and compliance audits.
• Support Pre-Startup Safety Reviews (PSSR) for new systems, facility modifications, and operational changes involving hazardous materials or energy systems.
• Conduct advanced hazard analyses including Job Hazard Analysis (JHA), Operating & Support Hazard Analysis (O&SHA), and operational risk assessments.
• Lead development, implementation, and oversight of emergency response plans and incident command activities related to hazardous operations and propulsion systems.
• Manage regulatory compliance programs related to OSHA, EPA, DOT, RCRA, SPCC, hazardous waste, air permitting, chemical inventory reporting, and environmental compliance obligations.
• Provide launch and test operation safety oversight in coordination with mission management, Range Safety, Fire Department personnel, and engineering teams.
• Mentor junior HSE personnel and provide technical guidance to operational teams and contractors.
• Develop and deliver advanced safety and process safety training programs including PSM awareness, Lockout/Tagout, Confined Space Entry, Fall Protection, Hazard Communication, Respiratory Protection, and Emergency Response.
• Evaluate contractor and subcontractor compliance with Firefly safety requirements and regulatory standards.
• Track and trend safety performance metrics, audit findings, near misses, corrective actions, and OSHA recordkeeping requirements.
• Support continuous improvement initiatives through audits, inspections, safety observations, and corrective action management systems.
• Participate in test readiness reviews, operational readiness reviews, and safety review boards.
• Travel to launch, manufacturing, and test facilities as required to support Firefly operations.

Qualifications

• Required: Bachelor’s degree in Occupational Health & Safety, Environmental Science, Engineering, Industrial Hygiene, Chemical Engineering, or related technical field.
• Required: 5+ years of progressive HSE experience supporting high-hazard industrial, aerospace, chemical processing, petrochemical, defense, or energy operations.
• Required: 3+ years of direct Process Safety Management (PSM) experience supporting highly hazardous chemical or propulsion-related operations.
• Required: Formal training or certification in Process Hazard Analysis (PHA), HAZOP facilitation, or Layer of Protection Analysis (LOPA).
• Required: Strong knowledge of OSHA Process Safety Management (29 CFR 1910.119) requirements and risk management principles.
• Required: Experience participating in or facilitating Process Hazard Analyses (PHA), HAZOPs, Management of Change (MOC), and Pre-Startup Safety Reviews (PSSR).
• Required: Advanced knowledge of OSHA, EPA, DOT, NFPA, ANSI, and hazardous materials regulations.
• Required: Demonstrated experience leading incident investigations and root cause analysis methodologies.
• Required: Experience developing and implementing emergency response plans and safety management systems.
• Required: Strong understanding of hazardous energy control, confined space entry, cryogenic systems, pressure systems, hazardous waste management, contractor safety management, and mechanical integrity programs.
• Desired: Certified Safety Professional (CSP), Certified Process Safety Professional, Certified Hazardous Materials Manager, or equivalent certification.
• Desired: Aerospace, launch operations, propulsion testing, or chemical processing experience.
• Desired: Experience supporting explosive, energetic, ordnance, or propellant operations.
• Desired: Experience implementing or auditing PSM programs in high-hazard operations.
• Desired: Familiarity with mechanical integrity programs and pressure system safety requirements.
• Desired: Prior Emergency Response Commander or Incident Commander certification.
• Desired: Experience with ISO 14001 and ISO 45001 management systems.
• Desired: Experience participating in Failure Review Boards, Mishap Investigation Boards, or operational readiness reviews.
• Desired: Familiarity with human factors engineering and ergonomic risk reduction practices.
• Additional Requirements: Must be willing to work extended hours, weekends, holidays, and off-shift schedules in support of test or launch operations. Must be capable of supporting field operations in outdoor environments and varying weather conditions. Ability to climb ladders, access elevated platforms, wear respiratory protection, and support physically demanding operational activities. Ability to travel as required between operational sites.

Pay

Firefly offers competitive compensation and benefits, including:

• Outstanding benefits for employees, including generous health, dental, and vision plans with low deductibles, parental leave, educational reimbursement, short-term disability, pet insurance, and flexible PTO options.

Schedule

Firefly operates on a flexible schedule to support its fast-paced development and test environment, which may require extended hours, weekends, holidays, and off-shift work.