Sr. Process Design Safety Engineer, EHS

The Sr. Process Safety Engineer (PSE) role at What To Expect Tesla is responsible for ensuring EHS milestones and deliverables are embedded during every phase of design, manufacturing, and commissioning for new vehicle, energy, solar, semiconductor, and AI programs. This role serves as a discipline lead for the EHS Engineering team, interacting with multi-disciplinary teams such as technology development, manufacturing engineering, factory design, facility engineering, and others.

About the Role

This position involves facilitating risk assessments for process and facility design, developing and implementing risk mitigation solutions, and owning hazardous material classification according to various agencies. It also requires producing detailed engineering reports and driving PSM requirements and solutions with cross-functional stakeholders.

Responsibilities

• Facilitate Risk Assessments for process and facility design: HAZOPs, FMEA studies, Dust Hazard Analyses (DHA), Equipment Safety Reviews, Layers of Protection Analysis (LOPA), Offsite Consequence Analysis (OCA)
• Develop and implement risk mitigation solutions for identified hazards, not limited to, mechanical ventilation and emission control systems, safety controls, emergency monitoring and life safety systems
• Implement the 14 elements of Process Safety Management to the design and commissioning of processes, focusing on Management of Change (MOC), Process Hazard Analysis (PHA), Process Safety Information (PSI), and Pre-Startup Safety Review (PSSR)
• Lead safety controls design (safety instrumented systems (SIS), e-stop logic, safe shutdown) by working closely with lead controls engineers and performing Safety Integrated Level calculations during design in accordance with IEC 61508
• Own hazardous material classification according to various agencies (CBC, CFC, NFPA, IBC, GHS, etc.) and utilize them to develop electrical classifications for equipment and surrounding areas and lead occupancy classification based on activities and hazards present
• Produce detailed engineering reports where needed (Life Safety, DHA, Fire Protection, PSV design basis, etc.)
• Drive PSM requirements and solutions with cross-functional stakeholders — including manufacturing engineering, controls, factory engineering, facilities, quality, and operations

Requirements

• Minimum 5 years of related work experience
• Experience leading or facilitating PHAs, HAZOPs, and Risk Assessments
• Experience reading and understanding Process and Instrument Diagrams (P&IDs), Process Flow Diagrams (PFDs), Architectural permit sets, CAD drawings
• Experience with functional safety (identifying safety instrumented levels (SIL) for safety instrumented systems (SIS)) and experience with SIL verification calculations
• Experience conducting and reviewing Pressure Relief Valve design basis calculations
• Working knowledge of OSHA, EPA and various state agency regulations, international regulations and interpretations, recommendations, and provides guidance for regulations across all EHS disciplines
• Experience meeting industry best practice guidance from: NFPA 652, NFPA 654, ISA 84, IEC 61508, IEC 65111, CCPS Risk Based Process Safety
• Ability to interact with interdisciplinary project teams and international partners with exceptional verbal and written communication skills, with the ability to communicate technical information in a concise way to a non-technical audience, and vice versa
• Ability to manage and organize multiple projects with competing priorities and different timescales (i.e.: checkpoints with long-term goals while completing shorter term goals)

Qualifications

• Degree in Engineering (Environmental, Safety, Chemical, Mechanical, Electrical or closely related industry), or equivalent experience

Skills

• Experience with functional safety (identifying safety instrumented levels (SIL) for safety instrumented systems (SIS)) and experience with SIL verification calculations
• Experience conducting and reviewing Pressure Relief Valve design basis calculations
• Working knowledge of OSHA, EPA and various state agency regulations, international regulations and interpretations, recommendations, and provides guidance for regulations across all EHS disciplines
• Experience meeting industry best practice guidance from: NFPA 652, NFPA 654, ISA 84, IEC 61508, IEC 65111, CCPS Risk Based Process Safety
• Ability to interact with interdisciplinary project teams and international partners with exceptional verbal and written communication skills, with the ability to communicate technical information in a concise way to a non-technical audience, and vice versa
• Ability to manage and organize multiple projects with competing priorities and different timescales (i.e.: checkpoints with long-term goals while completing shorter term goals)

Benefits

Benefits include competitive pay, medical plans, dental (including orthodontic coverage), vision plans, HSA contributions, flexible spending accounts (FSA), 401(k) with employer match, employee stock purchase plans, and other financial benefits. Tesla also offers company-paid basic life, AD&D, short-term and long-term disability insurance, an employee assistance program, sick and vacation time, and paid holidays. Additional benefits include commuter benefits, employee discounts and perks, and a variety of voluntary benefits such as critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance. Tesla also offers weight loss and tobacco cessation programs, a Tesla Babies program, and a commuter benefits program.