Process Safety Manager

Position Title: 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

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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