Process Safety Manager

Company: INEOS Olefins & Polymers USA Interested in joining a winning team? A team whose employees are empowered to make a difference? Process Safety Manager & Technical Authority (TA2) INEOS Olefins & Polymers USA Location: League City, Texas (hybrid) Grade: S1 Salary Range: Starting at $180,000 (commensurate with experience) Purpose of the Role The Process Safety Manager & Technical Authority is INEOS O&P USA’s most senior authority for process safety, regulatory compliance, and risk management. The role defines, governs, and enforces enterprise standards, programs, and work processes that protect people, assets, and the environment against the consequences of process safety incidents across more than $15B in enterprise replacement value. Decisions made in this role directly safeguard the company’s license to operate, regulatory compliance posture, and protection from catastrophic loss-of-containment events. The TA2 leads the corporate Process Safety function—a team of 6–10 professionals including Process Safety Advisors, Process Safety Engineers, and the enterprise SIS focal point—ensuring that OSHA PSM (1910.119), EPA RMP (40 CFR 68), INEOS 20 Principles, and INEOS Group Guidance Notes are consistently implemented, audited, and improved across all O&P USA manufacturing sites. The role shapes long-term process safety strategy, governs PHA/LOPA and risk assessment methodologies enterprise-wide, and ensures that process safety requirements are embedded into capital projects, turnaround planning, and operational decision-making. The Process Safety Manager exercises final decision-making authority on process safety program compliance, audit findings, and risk acceptance decisions, with decisions binding on site leadership. The position is also recognized across INEOS as a technical expert expected to engage in industry forums (AFPM, AIChE CCPS, TCC), stay ahead of emerging regulatory and industry expectations, and ensure O&P USA maintains leadership in process safety performance. Business Context INEOS O&P USA is a major contributor to INEOS Group performance—yet operates aging assets with significant variability in standards, work practices, and process safety maturity across sites. The enterprise is undergoing a major transformation to implement a corporate Operations Management System (OMS) and centralize discipline leadership through a new Engineering & Technology organization. This role is central to that change. The Process Safety Manager will help shift the organization from site-based autonomy to a unified enterprise model with consistent process safety standards, expectations, and discipline leadership. Success requires someone with deep regulatory and technical mastery, proven experience building and leading process safety programs across large manufacturing environments, and the resilience needed to drive cultural and technical change. The position serves as the single point of accountability for all process safety and risk management matters across O&P USA. Key Accountabilities Enterprise Process Safety Standards & Technical Governance Own and maintain enterprise process safety standards, programs, and work processes aligned with OSHA PSM, EPA RMP, INEOS 20 Principles, and IGGNs. Exercise final decision-making authority on process safety program compliance, risk acceptance, and audit findings, with decisions binding on site leadership. Govern all enterprise work processes related to PHA/LOPA, Management of Change (MOC), Pre-Startup Safety Review (PSSR), incident investigation, and PSM auditing. Serve as the Technical Authority and final approver for process safety decisions affecting regulatory compliance and risk posture across the enterprise. Approve all deviations from enterprise process safety standards and ensure appropriate risk mitigation is in place. Transformation & Change Leadership Define and execute the multi-year enterprise strategy for process safety, establishing the vision, objectives, and resource requirements to achieve top-quartile performance in regulatory compliance and risk management. Conduct a comprehensive assessment of the current O&P process safety programs against recognized industry best practices, regulatory expectations, and peer performance benchmarks. Identify serious gaps and high-priority risks, and define where standardization and improvement are essential. Lead the multi-year transformation to unify and elevate process safety management across O&P USA, aligning site-level programs into a consistent enterprise framework. Secure cross-site alignment from leadership teams, using governance authority and subject matter expertise to ensure execution of enterprise standards. Ensure that underlying process safety work processes and tools are aligned with best practices and able to deliver long-term aspirations in both compliance and risk reduction. PSM/RMP Compliance & Assurance Accountable owner of the OSHA PSM and EPA RMP compliance posture for O&P USA. Lead and coordinate the execution of PSM/RMP compliance audits with internal multi-disciplinary teams, ensuring findings are tracked, prioritized, and closed. Own the regulatory reporting and management of the EPA RMP 40 CFR 68 program. Conduct periodic assurance reviews of site-level process safety programs to assess effectiveness and consistency. Track, report, and monitor effectiveness of PSM programs through Key Performance Indicators and data analysis for identification of emerging trends and leading indicators. Ensure process safety risks are not deferred through inadequate mitigation or scope deletion. PHA/LOPA & Risk Assessment Governance Own and govern enterprise risk assessment methodologies, including PHA, LOPA, HAZID, Dust Hazard Analysis (DHA), and quantitative risk assessment. Ensure consistent application of PHA/LOPA methodologies, tools, and documentation standards across all sites. Review and approve complex or high-consequence risk assessment outcomes and associated recommendations. Ensure lessons learned from PHA/LOPA practices are captured, shared, and incorporated into enterprise guidance documents. Conduct periodic audits of PHA/LOPA studies, worksheets, and reports to verify quality and compliance. Risk Management Program Ownership Own and govern corporate programs for: facility siting, risk assessment, RMP Submission, MOC/PSSR, combustible dust, popcorn polymer, ALARP, Remote Operated Isolation Valves, dispersion modelling, Shelter-In-Place/Safe Havens, Capital Project Process Safety, and Fire Protection. Lead the development, integration, and implementation of IGGNs as they relate to process safety. Lead the coordination, documentation, and management of facility siting studies across all manufacturing sites. Ensure process safety requirements are embedded into capital projects through all stages of execution. SIS Lifecycle Governance & Oversight Provide governance and oversight of the enterprise Safety Instrumented Systems (SIS) lifecycle management program through the O&P USA SIS focal point, who reports within this function. Ensure SIS-related requirements from PHA/LOPA studies are properly translated into design, validation, and ongoing management of safety instrumented functions. Ensure alignment between process safety risk assessment outcomes and SIS capital investment priorities. Incident Investigation & Lessons Learned Lead or direct significant process safety incident investigations at manufacturing sites. Ensure root cause findings are translated into systemic corrective actions and shared across the enterprise. Integrate lessons from incidents, near-misses, audits, and peer benchmarking into continuous improvement of process safety programs. Monitor external incident trends (CSB, industry reports) and proactively assess applicability to O&P USA operations. Performance Monitoring & Continuous Improvement Track leading and lagging process safety indicators, including Tier 1 and Tier 2 events, demands on safety systems, overdue action items, and audit finding closure rates. Lead focused improvement initiatives addressing systemic process safety gaps. Report regularly to Engineering & Technology leadership and the O&P Board on process safety performance, critical risks, and investment recommendations. Drive year-over-year improvement in OMS Process Safety maturity scores. Functional Leadership & Team Development Lead and develop a central Process Safety team of 6–10 professionals, including Process Safety Advisors, Process Safety Engineers, and the enterprise SIS focal point. Define and maintain competency and training requirements for all process safety roles across O&P USA, serving as the accountable owner for these standards within the future Competency Management System. Foster a network of site-based process safety professionals to align execution, share learnings, and address systemic risks. Stay connected to site-level priorities and provide appropriate technical challenge, support, and advocacy. External Industry Leadership & Engagement Participate in, and where appropriate lead, INEOS Group discipline networks to ensure alignment, knowledge sharing, and adoption of best practices across the enterprise. Actively participate in external technical committees and industry organizations (e.g., AFPM, AIChE CCPS, TCC) to stay informed on emerging trends, regulatory developments, and threats. Represent INEOS’s interests in relevant industry discussions and regulatory forums. Bring forward external learnings and influence updates to internal systems as appropriate. Required Qualifications Education & Experience Bachelor’s degree in Chemical, Mechanical, or related engineering discipline (advanced degree preferred). 15+ years of progressive experience in process safety management in refining, petrochemical, or large-scale process industries, with at least 5 years in a corporate, division, or enterprise-level leadership role. Deep working knowledge of OSHA PSM (1910.119), EPA RMP (40 CFR 68), and applicable RAGAGEP. Proven leadership in building, leading, and improving process safety programs across multiple sites. Significant experience in PHA/LOPA facilitation, PSM auditing, and Management of Change governance. Demonstrated ability to set policy and drive compliance across large, diverse manufacturing organizations. Participation in external technical committees or industry networks strongly preferred. Technical Skills Recognized authority in process safety management and regulatory compliance. Deep expertise in PHA/LOPA methodologies, risk assessment, facility siting, and quantitative risk analysis. Strong technical knowledge of good engineering practices (e.g., CCPS, NFPA, API, ISA, ASME, FM Global) associated with risk management. Experience with Safety Instrumented Systems (SIS) lifecycle management and the interface between risk assessment and SIS design. Experience supporting TAR planning and capital projects from a process safety perspective. Familiarity with dispersion modelling techniques and software (e.g., PHAST, RMP*Comp, ALOHA). Strong judgment in high-stakes regulatory and engineering decisions. Ability to apply financial and commercial understanding to process safety investment decisions. Behavioral Skills High integrity, sound judgment, and technical courage. Strong ability to influence without direct authority across multiple levels and functions. Builds trust-based relationships with site leaders, engineers, and regulators. Excellent communication skills—able to translate complex regulatory and technical issues into business impact. Resilient change agent able to drive cultural and technical transformation. Sees systemic risk patterns across sites, not just individual findings. Maintains a long-term view while delivering near-term compliance and risk reduction improvements. Earns credibility by creating value—not just enforcing compliance. Builds capability in others through coaching, clarity, and structured follow-up. Location & Reporting This role is based in the Houston metropolitan area, supporting multiple INEOS O&P USA locations including the Battleground Manufacturing Complex in Deer Park, the Chocolate Bayou plant, and the Carson facility in California. Most locations are within driving distance, and the expectation is that this role spends the majority of time embedded at operating sites, providing hands-on technical leadership where process safety risk and compliance decision-making occur. A secondary presence is expected at the corporate office at Marina View in League City for collaboration with central teams and leadership. The position reports to the Engineering & Technology Manager and works in close partnership with site engineering, operations, maintenance, turnaround, and capital project leadership teams. The Process Safety Manager is a peer to the Equipment Integrity Manager and the Reliability & Machinery Technical Authority within the Engineering & Technology organization. The role leads a central process safety function of 6–10 professionals—including Process Safety Advisors, Process Safety Engineers, and the enterprise SIS focal point—and influences all site-based process safety personnel, PSM coordinators, and PHA/LOPA facilitators across the enterprise. Hybrid work is supported consistent with the INEOS O&P USA hybrid work policy, with the expectation that remote work is used to enhance productivity, while on-site presence remains essential to effectively support process safety programs, coach site personnel, and maintain strong engagement with operating teams. Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance. On our team, people are acknowledged for embracing new practices that help create real value for customers.