Job Description

The Process Safety Sr. Engineer - Regional Process Safety is responsible for application and implementation for ongoing compliance with Process Safety Standards, the regulatory Process Safety Management (PSM) standard and Risk Management Plan (RMP) programs. This position will interface with relevant third parties such as consultants and auditors retained by the Company as well as with facility and corporate leadership. This position requires very strong subject matter expertise regarding process safety and risk management planning, both as industrial disciplines as well as under the regulatory mandates for these areas. The position also requires a detailed understanding of facility operating, engineering, maintenance, and planning processes and the ability to identify and communicate PSM and RMP ramifications of existing, new, and modified processes. The position also requires an aptitude for "walking the plant" and partnering with company personnel, contractors, and visitors, to increase education on facility processes and PSM and RMP issues and solutions related to those processes. The position requires regular inerface with virtually all departments of the facility as well as interface with initiatives within Global and Regional Safety departments. This position reports directly to the Director of Process Safety Management and Mechanical Integrity with primary responsibility of the process safety program at the Calvert City, KY site.

PSM Program Management

1. Lead the Process Safety Management (PSM) program improvements and implementation of processes, through sharing and facilitating best practices among different plants and by creating the best means and/or channels for communications to serve this purpose. Responsible or co-responsible for application of all 14 elements of OSHA PSM standard.
2. Support/Develop business specific standards and best practice efforts.
3. Lead process safety implementation. Identify needs required to comply with PSM requirements and establish a Risk Based Process Safety approach.
4. Provide support for management of significant, though unregulated, process safety risks (e.g. not regulated because volume of chemical is below regulatory threshold) and process safety activities regulated under alternative regulatory regimes (e.g. PHMSA regulation of pipeline safety)
5. Assist site in their procedure development and provide direct support to their implementation efforts of new and existing standards (e.g., Process Safety Directives or Policies).
6. Report upon PSM/RMP activities and initiatives. Provide evaluations and progress reports of ongoing programs to management as required.
7. Support site and capital projects to ensure process safety requirements are identified in the project design and implementation.

1. Process Safety Training & Communication
2. Train and strengthen site process safety resources in their process safety related duties including process safety and specific Procedures, Directives, and Policies
3. Provide training to employees and contractors (as required) to assure understanding and compliance with legal obligation under PSM/RMP as well as conformance with Process Safety requirements.
4. Ensure contractor selection with strong safety and process safety mindsets (i.e. gatekeeper function) and be an active support ensuring safe work practices throughout contractors’ work on Company projects.

Safety Reviews, Audits, and Investigations

1. Lead or participate with required compliance audits of the PSM/RMP covered sites.
2. Assist site in leading Process Hazards Analysis (PHA) by providing expert support in PHA methodologies, such as WSA (Safety Analysis).
3. Provide support for LOPA reviews of those risk scenarios requiring further assessment post PHA review as requested by sites or projects.
4. Assist site with their Hazard Assessment (Off-Site Consequence Analysis) modeling in accordance with legal requirements (as required).
5. Assist in development of the Functional Safety program and establish the governance requirements for the program.
6. Track and follow-up action items with timely completion; addressing findings from PSM audits, PHA studies, and other PSM or RMP assessment activities.
7. Participate in select Pre-Startup Safety Reviews (PSSRs) prior to startup of new or modified processes or equipment or after extended shutdown of equipment. Periodically review site PSSRs for quality and completeness.
8. Participate in Process Safety event investigations/root cause analysis to provide guidance to all sites. In conjunction with site management teams, track progress of corrective actions.
9. Evaluate events and operational results and support the revising / updating of site policies, procedure revisions, and training to address process safety related findings.

1. Functional responsibility for MI program governance
2. Assist in developing and implementing policies for a robust mechanical integrity program.
3. Assist in development of and tracking KPIs for mechanical integrity processes
4. Assist site with compliance to the MI policy and development of site specific procedures.
5. Ensure training is developed and provided to the affected personnel for the MI program.
6. Assist in MI related compliance opportunities by ensuring the correct resources are utilized and the documentation is completed.
7. Support MI processes for site and capital projects.
8. Works closely with Site Mechanical Integrity team and Mechanical Integrity Quality Assurance and Control Specialist – Regional for MI QA/QC

What we need from you:

• Bachelor’s degree in engineering is required
• Minimum of 8 years’ experience in PSM and RMP best practices for petrochemical and/or chemical plants is required
• Relevant industry certifications for Process Safety such as API, CSP, CCPSC, etc.
• Expertise in Incident Investigation, Process Hazard Analysis, Facility Siting, Dust Hazard Analysis, or other relevant process safety programs
• Travel up to 20% of time may be required
• Demonstrated experience in implementing, and executing a PSM program
• Demonstrated experience in identifying and mitigating process safety risks
• Advanced experience in Process Hazard Analysis facilitation and execution.
• Demonstrated leadership and audit experience in PSM management positions in the chemical or petrochemical industry
• Detailed knowledge of U.S. (including federal, state and local) regulations related to process safety and risk management planning, particularly the OSHA PSM standard and the Clean Air Act’s RMP regulations.
• This position will need to have an understanding of relevant agency practices regarding enforcement of the standards and regulations (such as OSHA’s National Emphasis Programs for the chemical industry).
• The position will also contribute to, and perhaps lead, internal efforts to develop internal Policies, Practices, Procedures, Design Guides and Engineering Standards.
• In addition, the position requires participation in professional/technical organizations and in the development and delivery of subject matter training.
• A general understanding of related codes and consensus standards is also necessary (e.g. state fire, boiler, and pressure vessel codes; API, ANSI, ASME etc. standards and recommended practices) as these play a role in overall process safety management whether or not formally incorporated within the PSM and RMP standards.
• Analytical ability, organizational skills, time and people management skills, computer skills such as SAP, Word, Excel, PowerPoint, PHA Works, and must be an excellent communicator both orally and in writing.
• The person must be flexible, innovative, and have good leadership ability.

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