Safety Engineer

Role & responsibilities

1. Process Safety Management (PSM) Implementation and Oversight

• Develop and Implement PSM Programs: Oversee the implementation of Process Safety Management (PSM) programs, focusing on hazard identification, risk assessments, and accident prevention in the steel manufacturing process.
• Ensure Compliance with Regulations: Ensure that the steel plant adheres to national and international safety standards and regulations related to process safety, such as OSHAs PSM standard or other local safety laws and industry best practices.
• Risk Management: Identify, assess, and manage risks associated with steel production processes, particularly in areas like furnace operations, chemical processes, and metalworking machinery, where accidents could result in significant harm.

2. Hazard Identification and Risk Assessments

• Conduct Hazard Identification Studies: Regularly perform hazard identification exercises (HAZID) to identify potential hazards in the steel production processes, including chemical spills, equipment malfunctions, fire risks, and structural failures.
• Risk Assessments: Facilitate regular risk assessments (e.g., HAZOP, FMEA) to evaluate the risks of hazardous events occurring, such as explosions, chemical leaks, or mechanical failures, and develop action plans to mitigate these risks.
• Incident Investigation and Root Cause Analysis: Investigate accidents, near-misses, or unsafe practices to identify their root causes. Implement corrective actions to prevent recurrence of similar incidents.

3. Safety Procedures and Guidelines

• Develop Safety Procedures: Establish and enforce clear safety procedures for high-risk processes like blast furnaces, electric arc furnaces, rolling mills, and casting operations. These procedures should cover safe operational practices, emergency shutdowns, and troubleshooting protocols.
• Ensure SOP Adherence: Ensure all employees strictly follow Standard Operating Procedures (SOPs) related to process safety. Make sure these procedures are updated regularly in accordance with best practices and changes in the process.
• Emergency Response Planning: Develop and implement emergency response plans specifically designed for process-related incidents (e.g., chemical spills, fires, gas leaks). Ensure that all workers are trained to react quickly and appropriately in an emergency.

4. Process Safety Training and Awareness

• Safety Training Programs: Develop and deliver process safety training programs for all employees, contractors, and subcontractors working in process-related areas. This training should cover hazards, emergency procedures, safety equipment, and personal protective equipment (PPE) usage.
• Promote Safety Awareness: Create a safety culture within the organization by promoting continuous safety awareness among workers through campaigns, safety drills, and daily safety talks.
• Evaluate Training Effectiveness: Continuously assess the effectiveness of training programs and modify them based on feedback, changes in processes, or regulatory requirements.

5. Safety Inspections and Audits

• Conduct Safety Inspections: Perform routine inspections of equipment, machinery, and processes to ensure they are in safe operating condition and that safety standards are being met.
• Compliance Audits: Conduct regular audits of the plants operations to verify compliance with process safety standards, safety regulations, and internal safety procedures.
• Equipment Maintenance: Ensure that machinery, equipment, and safety devices such as fire suppression systems, gas detectors, and safety valves are maintained properly and regularly tested for functionality.

6. Incident Reporting and Documentation

• Document Safety Incidents: Ensure that all accidents, incidents, and near-misses are documented in detail, including root cause analysis and corrective actions taken.
• Safety Metrics and Reporting: Track key safety metrics such as accident frequency rates, near-miss incidents, and safety training participation. Report these metrics to management for continuous improvement.
• Record-Keeping: Maintain accurate records of safety inspections, audits, training, incident reports, and other safety-related documentation in accordance with regulatory requirements and company policies.

7. Safety Equipment and Personal Protective Equipment (PPE)

• Ensure Adequate PPE: Ensure that all employees working in high-risk process areas are provided with and use appropriate personal protective equipment (PPE) such as heat-resistant clothing, gloves, face shields, respiratory protection, and hearing protection.
• Safety Equipment Maintenance: Monitor the availability, maintenance, and proper functioning of process safety equipment, including fire extinguishers, emergency alarms, gas detectors, emergency shut-off systems, and first-aid kits.
• Conduct PPE Inspections: Regularly inspect PPE to ensure it is in good condition and replace any damaged or expired equipment.

8. Process Safety Documentation and Reporting

• Safety Procedures Documentation: Ensure that all safety-related procedures, manuals, and safety data sheets (SDS) are clearly documented, regularly updated, and easily accessible to employees.
• Incident Reporting: Implement a reporting system for employees to report safety hazards, near-misses, and unsafe work practices. Ensure that these reports are followed up with corrective actions.
• Regulatory Reporting: Ensure that all necessary safety-related reports are submitted to regulatory bodies in compliance with applicable laws and regulations.

9. Collaboration with Other Departments

• Work with Engineering Teams: Collaborate with engineering teams to review process designs, evaluate new technologies, and ensure that safety is incorporated into the design and operation of new processes and equipment.
• Coordinate with Maintenance: Work with the maintenance team to ensure that safety equipment and machinery are regularly inspected, serviced, and replaced as needed to ensure safe operation.
• Liaise with External Safety Experts: Collaborate with external safety consultants, auditors, and regulatory bodies to ensure compliance with process safety standards and to stay updated on industry best practices.

10. Continuous Improvement and Safety Culture Development

• Promote Continuous Improvement: Continuously seek ways to improve the process safety management systems by using feedback, audit results, incident investigations, and performance metrics.
• Foster Safety Culture: Develop and foster a strong safety culture within the plant by encouraging open communication about safety concerns, incentivizing safe behaviors, and recognizing teams or individuals who exemplify high safety standards.

Key Skills and Qualifications

• Technical Knowledge: Deep understanding of process safety management (PSM), steel manufacturing processes, and associated hazards such as chemical handling, high heat processes, and heavy machinery operations.
• Risk Management Skills: Ability to identify, assess, and mitigate risks associated with steel industry processes.
• Regulatory Knowledge: Familiarity with industry safety standards, regulations, and codes (e.g., OSHA PSM, HSE standards, ISO 45001, etc.).
• Analytical Skills: Strong skills in conducting risk assessments, incident investigations, and data analysis to improve safety processes.
• Training and Communication: Ability to design and deliver effective safety training programs and communicate safety procedures clearly to all levels of the workforce.
• Problem-Solving Skills: Ability to quickly address safety issues, investigate incidents, and implement corrective actions effectively.
• Attention to Detail: Ensuring safety standards are met at every step, from planning to implementation and monitoring.