Manager - Process Safety

TPC•Houston, TX

10h

About The Position

The Corporate Manager, Process Safety Management (PSM) is accountable for establishing, governing, and continuously improving TPC Group’s enterprise process safety framework. This role leads implementation and assurance of OSHA Process Safety Management (29 CFR 1910.119) requirements and EPA Risk Management Program (RMP, 40 CFR Part 68), including submittals, updates, and emergency coordination, and will serve as the corporate owner for process safety management requirements of the TPC Group EPA RMP Consent Decree. In addition, the role will manage and develop process safety management staff direct reports.

Requirements

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 multiâsite oversight.
Demonstrated expertise with OSHA PSM (29 CFR 1910.119) and EPA RMP (40 CFR Part 68) , including RMP submittals/updates and PHA governance.
All applicants must be eligible to work for any employer in the United States without needing any company sponsorship

Nice To Haves

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.

Responsibilities

Program Ownership & Governance (PSM & RMP)
Own the TPC Group PSM program and its 14 elements (e.g., PSI, PHA, Operating Procedures, Training, Mechanical Integrity, MOC, PSSR, Incident Investigation, Compliance Audits, Contractor Management, Hot Work, Emergency Planning/Response), assuring 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 (e.g., §§68.150–68.195 for RMP and §1910.119 for PSM)
EPA RMP Consent Decree Compliance
Serve as the TPC Group program manager for all consent decree obligations, including implementation of risk management improvements, reporting requirements, stipulated timelines, and penalty avoidance; coordinate with Legal, Operations, and Engineering to ensure corrective actions are prioritized and verified.
Ensure timely, accurate reporting and document retention per decree requirements (e.g., compliance milestones, audits, incident investigations, and program certifications) and maintain readiness for DOJ/EPA oversight.
Process Hazard Analysis (PHA) & Risk Reduction
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.
Mechanical Integrity & Change Management
Collaborate with company SME’s to set corporate MI standards (asset criticality, inspection/PM, deficiency management, proof testing, fitness for service), ensuring alignment with OSHA PSM and enhanced RMP expectations.
Govern Management of Change (MOC) quality and timeliness (design basis, PSI updates, procedures, training, PSSR), focusing on preventing uncontrolled changes that elevate risk.
Incident Investigation, Lessons Learned & Transparency
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.
Emergency Preparedness & Community Interface
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.
Auditing, Assurance & Reporting
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) and annual corporate PSM/RMP performance reports.
Training & Competency
Collaborate with training department to develop competency standards and training matrices for operators, maintenance, engineers, and leadership covering PSM elements, RMP requirements, emergency response, and consent decree obligations.