Process Safety Engineer – Relief & Flare Systems

Location: Houston, TX


Ø Act as the primary contact for Pressure Relief & Flare Systems in the plant, leading the revalidation cycle for process units, maintaining updated relief systems & flare models, analyzing and advising on overpressure and under pressure situations, designing relief systems, and documenting all necessary information.

Ø Serve as an expert in pressure relief and flare systems procedures, regulatory codes & standards, and stay updated on industry best practices and standards. Utilize knowledge and industry information to continually improve process safety and reduce risks.

Ø Assist in the design, sizing, and evaluation of pressure relief systems and flare headers, resolving any existing deficiencies and designing new systems if necessary.

Ø Provide technical support for the Management of Change (MOC) and Pre-start Up Safety Review (PSSR) processes, ensuring that relief protection is adequately addressed and documented for all process changes.

ØConduct engineering analyses, such as hydraulics, relief & flare calculations, and dispersion modeling, to ensure compliance with process safety regulations and promptly address any identified gaps.

ØProvide technical guidance and oversight for special operation activities, including decontamination, startups, and shutdowns, to ensure process safety at all times.

ØLead the development, implementation, review, and maintenance of PSM site procedures, technical guidelines, and internal standards to achieve compliance and further reduce risks.

ØParticipate in PSM compliance audits and interface with regulatory agencies as required for PSM-related matters.

ØWork on resolving open PSM action items and implementing corrective actions for audit findings.

ØConduct field and behavioral observation audits, as well as risk assessments and mitigation strategies.

ØDevelop and mentor others to enhance process safety capabilities throughout the organization, including conducting training sessions and creating training materials for employees at all levels.

The Relief & Flare Systems Engineer plays a vital role in ensuring compliance with OSHA PSM and reducing risks in the plant. This position involves interacting with various disciplines and organizational levels, promoting a culture of process safety and continuous learning, and striving for top-notch PSM performance.


vBachelor of Science degree in Chemical Engineering or a related field is required, with a minimum of 10 years' experience. Consideration will be given to candidates with less experience but exceptional qualifications.

vPreference for applicants based in the Houston, TX area. No relocation assistance available.

vProficient in designing relief valves and flare systems.

vStrong understanding of basic refinery processes and elements of PSM.

vThorough knowledge of OSHA rules related to PSM.

vFamiliarity with process simulation software and relief systems management tools.

vKnowledgeable in process engineering and able to serve as a Technical Authority for reviewing and approving process safety designs by contractors and peers. Minimum 3 years of PSM experience in the petrochemical and/or refining industry required.

vExperience initiating, supporting, or leading Management of Change (MOC) work process.

vKnowledge of relevant codes and industry standards.

vFamiliarity with industry best practices.

vStrong attention to detail.

Effective communication skills, both written and verbal.

This role requires the ability to work effectively both remotely and virtually. Some weekend and evening support may be necessary for emergencies and operational issues.

Must have legal authorization to work full-time in the US for any employer besides the current one.

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