Process Safety Advisor

INEOS USA LLC; League City (TX); Hybrid; USD 127,800 - 156,200; Full time

Job summary

INEOS USA LLC is seeking a Process Safety Advisor in League City, Texas, to support and enhance process safety and risk management across multiple manufacturing sites. The role involves overseeing compliance with OSHA and EPA regulations, leading audits, and providing technical guidance. Candidates should possess significant experience in process safety management, PHA/LOPA facilitation, and risk assessment methodologies.

This hybrid position emphasizes both remote work flexibility and on-site leadership to ensure effective process safety practices. A Bachelor's in an engineering discipline and at least 10 years in a relevant field are required.

Qualifications

• Minimum of 10 years’ experience in the Chemical, Petrochemical, or Refining Industry.
• Deep familiarity with federal regulations related to Process Safety.
• Significant experience in facilitating complex PHAs and LOPAs.

Responsibilities

• Support and advance company compliance toward regulatory PSM/RMP.
• Lead execution of PSM/RMP Compliance Audits.
• Provide training and mentorship on process safety programs.

Skills

Process Safety Management

Risk Assessment

Compliance Auditing

PHA/LOPA Facilitation

Technical Leadership

Education

Bachelor’s degree in Chemical, Mechanical, Electrical Engineering or equivalent

Tools

PHA Pro

PHAST

RMP*Comp

ALOHA

CAMEO

Job description

Process Safety Advisor

INEOS Olefins & Polymers USA – League City, Texas (hybrid). Grade: H36/37. Salary Range: Starting at $142,000 (commensurate with experience).

Purpose of the Role

The Process Safety Advisor provides deep technical expertise and hands‑on leadership in support of INEOS O&P USA’s process safety and risk management programs. Working within the corporate Process Safety function, this role supports the development, implementation, and continuous improvement of programs related to OSHA Process Safety Management (PSM 1910.119), EPA Risk Management Program (RMP 40CFR68), INEOS 20 Principles (20P), and INEOS Group Guidance Notes (IGGN) across all manufacturing sites.

The Process Safety Advisor delivers authoritative guidance, training, and mentorship to site personnel and PSM team members in regulatory compliance and risk management best practices. The role supports company‑wide process safety performance by influencing and providing technical leadership to help move the organization to the next level of performance in process safety, risk assessment, and regulatory compliance.

Key responsibilities include applying regulatory knowledge, risk assessment methodologies, and good engineering practices across three major manufacturing sites and the O&P USA division office. The Process Safety Advisor serves as a key technical resource on facility siting, PHA/LOPA methodologies, dispersion modelling, MOC/PSSR, and capital project process safety requirements—helping to ensure that risk management is embedded into all phases of design, operation, and change management.

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. 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. The Process Safety Advisor plays an important role in this change.

Working under the direction of the Process Safety Manager, the role helps drive consistency in process safety programs across all sites, supports alignment with regulatory and corporate expectations, and contributes to the transition from site-based autonomy to a unified enterprise model.

Key Accountabilities

PSM/RMP Compliance & Continuous Improvement

• Support and advance company and site compliance toward regulatory (PSM/RMP) and internal (20P/IGGN/Corporate) process safety and risk management programs.
• Support corporate Operations Management System program development and implementation as it relates to process safety and risk management.
• Lead and coordinate the execution of PSM/RMP Compliance Audits with internal multi-disciplinary teams.
• Support the regulatory reporting and management of the EPA RMP 40CFR68 program.
• Track, report, and monitor effectiveness of PSM programs through Key Performance Indicators and data analysis for identification of emerging trends and leading indicators.
• Provide training and mentorship to appropriate personnel on the delivery and sustainability of process safety programs.
• Participate on the Process Safety Committees for each manufacturing site.
• Lead or support significant incident investigations at manufacturing sites.
• Participate in trade/industry organizations (e.g., AFPM, TCC, AIChE CCPS) and monitor regulatory updates (OSHA, EPA, CSB) to communicate emerging process safety trends and impacts to the company and stakeholders.

Process Hazard Analysis (PHA) & Layer of Protection Analysis (LOPA)

• Support the continuous monitoring and improvement of risk assessment methodologies, including PHA, LOPA, HAZID, and Dust Hazard Analysis (DHA).
• Provide oversight and guidance to personnel assigned to facilitate PHA/LOPAs.
• Train and mentor personnel in corporate methodologies, tools, and practices used to conduct PHA/LOPAs.
• Capture and share lessons learned from PHA/LOPA practices and incorporate changes into PSIM Guidance Documents and associated tools.
• Conduct periodic audits of PHA/LOPA studies, worksheets, and reports.
• Provide technical leadership in the resolution and application of PHA/LOPA tools when evaluating complex scenarios.
• Facilitate PHA/LOPAs as needed.

Risk Management Program Support & Technical Expertise

• Support and deliver corporate programs, and serve as a technical resource 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.
• Support development, integration, and implementation of IGGNs.
• Lead coordination, documentation, and management of facility siting studies and resolution of associated action items.
• Support PSIM team, manufacturing sites, and project teams in the evaluation of complex scenarios using qualitative and quantitative risk evaluation tools.

Technical Support & Good Engineering Practices

• Support manufacturing sites and act as a focal point for best‑in‑class delivery of process safety requirements for capital projects through all stages of execution.
• Review literature and provide technical interpretations (e.g., OSHA, EPA RMP, API, NFPA, ISA, ASME, CSB) for a broad range of site and corporate personnel.
• Champion and maintain enterprise process safety software solutions and databases.
• Interface with SIS Engineers, RV Engineers, and Mechanical Integrity roles as it relates to PHA/LOPA and PSM Auditing requirements.

Required Qualifications

• Education & Experience: Bachelor’s degree in Chemical, Mechanical, Electrical, or equivalent engineering discipline (advanced degree preferred). Minimum of 10years’ experience in Chemical, Petrochemical, or Refining Industry with direct accountability for Process Safety Management delivery or management.
• Regulatory Knowledge: Deep familiarity with federal regulations relative to Process Safety (US‑OSHA PSM1910.119 and US‑EPA RMP40CFR68).
• PHA/LOPA Expertise: Significant experience in facilitating complex PHAs/LOPAs and Management of Change sessions.
• Program Delivery: Proven track record of contributing to the delivery of industrial process safety programs and supporting policy implementation to drive compliance across large, diverse organizations.
• Industry Participation: Participation in external technical committees or industry networks strongly preferred.
• Technical Skills: Strong technical knowledge of good engineering practices (CCPS, NFPA, API, EPA, ASME, ISA, FM Global) associated with risk management; expertise in PHA/LOPA facilitation, risk assessment methodologies, and regulatory compliance program design; ability to lead large multi-disciplinary teams and deliver compliance audits with actionable recommendations; strong software proficiency with PHA Pro, PHAST, SharePoint‑based PSM platforms, and dispersion modelling tools (RMP*Comp, ALOHA, CAMEO); ability to comprehend, analyse, and interpret legislation and develop compliance programs; experience supporting capital project process safety requirements; strong judgment in high‑stakes engineering and regulatory decisions.
• Behavioral Skills: High integrity, sound judgment, and technical courage; strong ability to influence without direct authority; builds trust across functions and levels; excellent communication skills—effective and succinct in both verbal and written form; resilient change agent able to promote and inspire others to embrace change and drive continuous improvement; proven performance in project management and leading in an environment of competing and changing priorities; maintains a mindset of continuous improvement and curiosity; earns credibility by creating value—not just enforcing compliance.

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. The role spends significant time at operating sites, providing hands‑on process safety leadership. 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 Process Safety Manager and works in close partnership with site engineering, operations, maintenance, turnaround, and capital project leadership teams.

Other

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.