Manager - Process Safety

Core Responsibilities

• Own the TPC Group PSM program and its 14 elements, ensuring consistent standards and performance across facilities.
• Own the TPC Group RMP programs (40 CFR Part 68), including development, certification, submittal, updates/corrections, offsite consequence analyses, five-year accident history, prevention programs (Program 2 & 3), and emergency response program/exercises.
• Maintain auditable documentation and controls to meet PSM/RMP requirements.
• Serve as the TPC Group program manager for all consent decree obligations, coordinating with Legal, Operations, and Engineering to ensure corrective actions are prioritized and verified.
• Ensure timely, accurate reporting and document retention per decree requirements.
• Lead corporate standards and assurance for PHAs and HAZOPS, including revalidation cycles, closure of recommendations, and integration of incident learnings and external industry events.
• Oversee Safer Technology and Alternatives Analyses (STAA) and hierarchy of controls assessments for RMP covered processes, aligning with EPA’s “Safer Communities by Chemical Accident Prevention (SCCAP)” final rule emphasis on practicability of inherently safer design.
• Collaborate with company SMEs to set corporate MI standards (asset criticality, inspection/PM, deficiency management, proof testing, fitness for service).
• Govern Management of Change (MOC) quality and timeliness, focusing on preventing uncontrolled changes that elevate risk.
• Collaborate with Operational Excellence to establish and administer robust incident/near miss investigation protocols with root cause analysis, corrective action tracking, and communication of learnings to employees and contractors.
• Implement mechanisms for employee engagement and transparent communication on PHA findings, audits, and accident investigations.
• Support emergency response planning and exercises with site ERT/ICS, mutual aid (e.g., Channel Industries Mutual Aid), and local responders.
• Ensure plans meet RMP requirements and address worst case/alternative scenarios and community notification.
• Support internal PSM/RMP audits; oversee third party audits where needed; ensure triage and closure of findings; certify RMP submissions and maintain readiness for OSHA/EPA/TCEQ inspections.
• Maintain KPI dashboards for presentation to plant and executive leadership (event rates, PHA backlog, MI overdue items, MOC cycle time, audit closure).
• Implement training and competency standards for operators, maintenance, engineers, and leadership covering PSM elements, RMP requirements, emergency response, and consent decree obligations.

Required Qualifications

• Bachelor’s degree in Chemical Engineering, Mechanical Engineering, or related discipline; advanced degree preferred.
• 10+ years in process safety leadership within petrochemical/chemical manufacturing with multi-site oversight.
• Demonstrated expertise with OSHA PSM (29 CFR 1910.119) and EPA RMP (40 CFR Part 68), including RMP submittals/updates and PHA governance.

Preferred Qualifications

• Professional Engineer (PE) licensure or CCPS certifications (e.g., CPSA/CPSE).
• Hands-on experience with STAA, LOPA, SIL/functional safety, and asset integrity programs.
• Experience executing obligations under a federal Consent Decree (or equivalent enforcement orders), preferably with EPA/DOJ interface.

Leadership Competencies

• Strategic Risk Leadership: Able to translate regulatory obligations (PSM/RMP/Consent Decree) into practical, prioritized, and funded programs.
• Assurance & Accountability: Builds robust governance and reporting; ensures closure of findings and sustainable compliance.
• Stakeholder Engagement: Credible with regulators, community stakeholders, and internal leaders.
• Policy & Procedure Development: Demonstrated ability to write, develop, implement, and manage corporate procedures, policies, and standards that align with OSHA PSM, EPA RMP, and consent decree requirements, ensuring clarity, consistency, and operational compliance across all sites.