Process Safety Manager

Department: Health, Safety, Environment & Fire (HSE/F)

Reports To: General Manager HSE/F

Job Purpose

• To develop, implement, monitor, and continuously improve the Process Safety Management (PSM) framework to prevent catastrophic incidents involving hazardous chemicals, energy sources, and operational processes.
• The role ensures compliance with regulatory requirements, industry best practices, and company standards while safeguarding people, assets, environment, and business continuity.
• The successful Process Safety Manager should be able to proactively identify and controls major accident hazards, drives process safety excellence, ensures regulatory compliance, strengthens operational discipline, and fosters a culture where safety-critical risks are effectively managed to achieve Zero Harm, Asset Protection, Environmental Stewardship, and Sustainable Plant Reliability.

Key Responsibilities

Process Safety Management System Governance:

• Develop, implement, and maintain the Process Safety Management (PSM) framework.
• Ensure compliance with company policies, international standards, and statutory requirements.
• Establish process safety objectives, KPIs, and performance monitoring systems.
• Coordinate periodic PSM audits, assessments, and management reviews.

Hazard Identification & Risk Management:

• Lead HAZOP, HAZID, What-If, Bowtie, LOPA, and Risk Assessment studies.
• Identify process hazards and implement risk mitigation measures.
• Ensure critical risks are documented and adequately controlled.
• Monitor effectiveness of process safety barriers and safeguards.

Process Safety Assurance:

• Manage Process Safety Performance Indicators (Leading and Lagging Indicators).
• Monitor process safety trends and recommend corrective actions.
• Verify compliance with operating envelopes and safe operating limits.
• Conduct periodic field verification and compliance inspections.

Management of Change (MOC):

• Administer and govern the Management of Change process.
• Review and approve technical changes affecting plant safety.
• Ensure risk assessments are completed prior to implementation.
• Verify appropriate documentation, training, and communication before startup.

Incident Investigation & Learning:

• Lead investigations of process safety incidents and near misses.
• Conduct Root Cause Analysis (RCA) using recognized methodologies.
• Develop corrective and preventive action plans.
• Drive implementation and closure of investigation recommendations.

Asset Integrity & Reliability Coordination:

• Collaborate with Engineering, Inspection, and Maintenance teams.
• Ensure critical equipment inspection and testing programs are implemented.
• Support integrity management initiatives for pressure vessels, pipelines, tanks, and safety systems.
• Monitor effectiveness of preventive maintenance programs.

Emergency Preparedness & Response:

• Support development of emergency response and contingency plans.
• Participate in emergency drills and readiness assessments.
• Ensure process safety scenarios are incorporated into emergency planning.
• Strengthen organizational preparedness for major hazard incidents.

Competency Development & Safety Culture:

• Develop process safety awareness programs.
• Facilitate training on PSM elements and major accident prevention.
• Coach managers, supervisors, and plant personnel on process safety responsibilities.
• Promote a strong process safety culture across the organization.

Regulatory Compliance & Stakeholder Engagement:

• Interface with regulatory bodies and external auditors.
• Ensure compliance with applicable process safety regulations.
• Maintain accurate process safety documentation and reports.
• Provide technical advice on process safety matters.

Continuous Improvement:

• Benchmark against industry best practices.
• Conduct gap analysis and improvement initiatives.
• Support digitalization of process safety processes.
• Drive lessons learned implementation across plant operations.

Educational Qualifications

• Bachelor's Degree in Chemical Engineering, Mechanical Engineering, Petroleum Engineering, Industrial Engineering, or related field.
• Master's Degree in Process Safety, Engineering Management, Risk Management, or related discipline as additional advantages.

Professional Certifications - desirable of any:

• Certified Process Safety Professional (CCPSC)
• NEBOSH Process Safety Management
• Certified Functional Safety Engineer (CFSE)
• IOSH Managing Safely
• ISO 45001 Lead Auditor
• Risk Management Certification
• Incident Investigation Certification.

Required Experience:

• 8-15 years relevant industrial experience.
• Minimum 5 years in Process Safety Management.
• Experience in Fertilizer, Petrochemical, Oil & Gas, Chemical, Refinery, LNG, or Manufacturing Industries.
• Proven experience in HAZOP, LOPA, MOC, RCA, and Asset Integrity programs.

Technical Competencies:

• Process Safety Management (PSM)
• HAZOP Studies
• Layer of Protection Analysis (LOPA)
• Quantitative Risk Assessment (QRA)
• Bow-Tie Analysis
• Root Cause Analysis (RCA)
• Management of Change (MOC)
• Asset Integrity Management
• Emergency Response Planning
• Regulatory Compliance
• Process Hazard Analysis (PHA)
• Safety Instrumented Systems (SIS)
• Risk-Based Inspection (RBI)
• Process Safety Performance Metrics

Behavioral Competencies:

• Leadership & Influence
• Strategic Thinking
• Decision Making
• Problem Solving
• Analytical Thinking
• Communication Skills
• Stakeholder Management
• Coaching & Mentoring
• Attention to Detail
• Team Collaboration
• Integrity & Accountability
• Continuous Improvement Mindset.