HSE Engineer III - Process Safety Management

Firefly Aerospace•Briggs, TX

1d•Onsite

About The Position

The HSE Engineer III serves as a senior technical authority for environmental, health, safety, and Process Safety Management (PSM) support for Ground Support Equipment (GSE), propulsion test systems, and test operations at Firefly Aerospace’s Briggs, Texas facility. The role provides strategic oversight and technical guidance for high-hazard operations involving cryogenic and pressure systems, hazardous chemicals, propellants, fluid systems, energized equipment, and complex test infrastructure. It partners with GSE Engineering, Test Operations, Facilities, Propulsion, and Maintenance to integrate safety into the design, installation, operation, maintenance, and modification of test stands and support systems. The position drives operational risk reduction, regulatory compliance, emergency preparedness, and continuous improvement across test and GSE operations. It leads hazard analyses, supports process safety initiatives, oversees contractor and operational safety compliance, and integrates safety requirements into test planning and execution. The role operates with minimal supervision, mentors junior HSE personnel, influences safety culture, and supports Firefly’s fast-paced development and test environment. It is based in Briggs, Texas, with travel to launch, manufacturing, and test facilities as required. The role requires a bachelor’s degree in a relevant technical field and substantial HSE and PSM experience supporting high-hazard operations. The successful candidate will provide technical leadership across PSM, risk assessment, incident investigation, emergency response, environmental and regulatory compliance, training, contractor safety, and operational readiness. Extended hours, weekends, holidays, and off-shift schedules may be required to support test or launch operations.

Requirements

Bachelor’s degree in Occupational Health & Safety, Environmental Science, Engineering, Industrial Hygiene, Chemical Engineering, or a related technical field.
At least 5 years of progressive HSE experience supporting high-hazard industrial, aerospace, chemical processing, petrochemical, defense, or energy operations.
At least 3 years of direct PSM experience supporting highly hazardous chemical or propulsion-related operations.
Formal training or certification in PHA, HAZOP facilitation, or LOPA.
Strong knowledge of OSHA PSM requirements under 29 CFR 1910.119 and risk management principles.
Experience participating in or facilitating PHAs, HAZOPs, Management of Change, and Pre-Startup Safety Reviews.
Advanced knowledge of OSHA, EPA, DOT, NFPA, ANSI, and hazardous materials regulations.
Demonstrated experience leading incident investigations and root cause analysis methodologies.
Experience developing and implementing emergency response plans and safety management systems.
Strong understanding of hazardous energy control, confined space entry, cryogenic and pressure systems, hazardous waste management, contractor safety management, and mechanical integrity programs.
Ability to lead cross-functional teams and influence operational decision-making.
Strong written and verbal communication skills, including experience presenting to leadership teams.
Must be willing to work extended hours, weekends, holidays, and off-shift schedules in support of test or launch operations.
Must be able to support field operations outdoors and in varying weather conditions, climb ladders, access elevated platforms, wear respiratory protection, and support physically demanding operational activities.
Ability to travel between operational sites as required.
Must be a U.S. citizen, lawful permanent resident, protected individual under 8 U.S.C. 1324b(a)(3), or eligible to obtain required U.S. Department of State authorizations under applicable export regulations.

Nice To Haves

Certified Safety Professional, Certified Process Safety Professional, Certified Hazardous Materials Manager, or equivalent certification.
Aerospace, launch operations, propulsion testing, or chemical processing experience.
Experience supporting explosive, energetic, ordnance, or propellant operations.
Experience implementing or auditing PSM programs in high-hazard operations.
Familiarity with mechanical integrity programs and pressure system safety requirements.
Prior Emergency Response Commander or Incident Commander certification.
Experience with ISO 14001 and ISO 45001 management systems.
Experience participating in Failure Review Boards, Mishap Investigation Boards, or operational readiness reviews.
Familiarity with human factors engineering and ergonomic risk reduction practices.

Responsibilities

Lead development, implementation, and continuous improvement of HSE and PSM programs supporting propulsion testing, hazardous operations, and launch activities.
Serve as the senior HSE and PSM subject matter expert for high-risk operations involving propellants, cryogenics, pressure systems, hazardous chemicals, and energized systems.
Manage and maintain applicable OSHA Process Safety Management program elements under 29 CFR 1910.119.
Facilitate and participate in PHAs, What-If analyses, HAZOPs, LOPAs, and other formal risk assessments.
Partner with engineering and operations teams to incorporate process safety into system design, modifications, Management of Change, and operational readiness.
Lead incident investigations and root cause analyses; develop corrective actions and implement lessons learned.
Develop and maintain PSM documentation, including operating procedures, safe work practices, process safety information, mechanical integrity records, and compliance audits.
Support Pre-Startup Safety Reviews for new systems, facility modifications, and operational changes involving hazardous materials or energy systems.
Conduct Job Hazard Analyses, Operating & Support Hazard Analyses, and operational risk assessments.
Lead development and oversight of emergency response plans and incident command activities for 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 obligations.
Serve as the primary interface with regulatory agencies, auditors, emergency responders, and external safety organizations.
Provide launch and test operation safety oversight 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 safety and process safety training, 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 metrics, audit findings, near misses, corrective actions, and OSHA recordkeeping requirements.
Participate in test readiness reviews, operational readiness reviews, and safety review boards.
Support continuous improvement through audits, inspections, safety observations, and corrective action management systems.
Travel to launch, manufacturing, and test facilities as required.
Support field operations in outdoor environments and varying weather conditions; climb ladders, access elevated platforms, wear respiratory protection, and participate in physically demanding operational activities as needed.