Process Safety Engineer

Process Safety Engineer – Job Overview

The Process Safety Engineer will be responsible for complex technical work in a wide range of EHS disciplines. They will serve as discipline lead for the EHS team, interacting with many multi‑disciplinary teams (e.g., manufacturing engineering, materials development, chemical engineering, factory design, facility engineering, etc.); ensure regulatory compliance can be met in new and proposed changes to equipment and processes, facilities and designs;

perform process and facility risk assessments, and implement Tesla EHS and industry best practices. They will play a key role in the sustainable design, change managed operation of Tesla’s business.

The overall charter is risk and hazard reduction and pollution prevention across all operations. The ideal candidate takes pride in their knowledge of process, regulations, analytical abilities, organizational skills, attention to detail, and ability to solve problems quickly and creatively.

• Serve as the subject matter expert for all process safety‑related matters across Tesla’s Texas operations
• Oversee the implementation and continuous improvement of PSM programs in accordance with OSHA 29 CFR , EPA RMP: 40 CFR 68, American Institute of Chemical Engineer CCPS, and international best practices (ISO 45001 and API RP 754)
• Ensure full regulatory compliance with applicable local, state, national, and international safety regulations
• Lead Process Hazard Analyses (PHA) such as HAZOP, Layers of Protection Analysis (LOPA), What‑If, Failure Modes and Effect Analysis (FMEA), and ensure timely closure of action items
• Champion Management of Change (MOC) processes to assess potential hazards before implementation
• Lead quantitative and qualitative risk assessments including Quantitative Risk Assessment (QRA), Safety Integrity Level (SIL), and Bow‑Tie Analysis
• Develop and maintain safe operating limits and critical safety documentation (e.g., Relief System Design, Safety Instrumented Systems, Model Dispersion, Facility Siting)
• Direct root cause investigations of process safety incidents and near‑misses, ensuring lessons learned are implemented organization‑wide
• Provide technical safety input and approvals during Front‑End Engineering Design (FEED), Detailed Design, and Operations using inherently safer design principles
• Collaborate with operations, maintenance, and engineering to ensure safe plant operation, commissioning, and startup
• Collaborate with Tesla global process safety team

• Bachelor’s Degree in Process Safety, Chemical, Mechanical, Environmental Engineering or equivalent; master’s degree or PE license preferred
• 6+ years of experience in process safety engineering in oil & gas, petrochemical, chemical manufacturing, or similar high‑hazard industries. Seek experienced field personnel over management directing personnel
• Previous experience managing EHS risks associated with ion battery manufacturing, cathode manufacturing, or lithium refining preferred
• Proven track record of leading PHA/HAZOP/DHA studies and implementing PSM programs
• Advanced understanding of relevant regulations (e.g., OSHA PSM, EPA RMP) and industry standards (e.g., API, NFPA 497, 499, & 660, NEC 70E & 70B, ASME, ANSI, CCPS, and RBPS)
• Strong knowledge of risk assessment methodologies and process safety tools
• Certified Functional Safety Expert (CFSE) or Certified Process Safety Professional (CCPSC) is a strong advantage
• Familiarity with process safety software (PHA‑Pro, PHAST, DNV HAZID/HAZOP, BowTieXP, etc.)
• Strong communication, leadership, and team development skills
• Demonstrated ability to influence senior stakeholders and build a culture of safety excellence

• Experience with major industry players (Dow, Phillips 66, Exxon Mobil, BASF, Chevron, DuPont)
• Ability to hit the ground running with minimal supervision
• Strong analytical skills and collaboration experience

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances.