Sr. Global Process Safety Engineer

Job Description

Stepan is hiring a Sr. Global Process Safety Engineer for our Millsdale, IL site. This position has a close connection to the sites with focus on the execution of Stepan’s initiatives to enhance Process Safety performance. The Global Process Safety Engineer provides technical expertise, has a holistic view of the plants capabilities and opportunities, and oversees Process Safety programs.

Process Safety Management (including OSHA PSM and EPA RMP)
• Provide active technical and management support to the sites related to the implementation and maintenance of Stepan standards and procedures.
• Provide input for the identification of new standards needed.
• Engage with EHS&S Excellence team providing feedback on new standards and participate in the preparation of the roll-out plan.
• New standards rollout and training to sites.
• Participate in the elaboration of RAGAGEPS by external committees (e.g. API, NFPA, CCPS).
• Provide Process Safety expertise in:
o Reactive chemistry, including emergency venting.
o Safe handling of flammable liquids and combustible dusts.
• Support sites with the implementation of OSHA PSM elements by:
o Sharing good practices identified in Stepan’s network.
o Provide guidance and clarification related to the regulatory aspects of OSHA PSM.
o Identify common gaps across sites and propose solutions / tools to address them.
Compliance and Auditing
• Participate in OSHA PSM, EPA RMP and Stepan Process Standards audits across Stepan’s network.
• Provide active technical support to sites to close PSM/RMP recommendations from the audits, especially related to complex solutions. 
• Take a leadership role supporting closure of critical findings related to Process Safety and ensure quality and adequacy of solution.
• Act as verifier of Major findings ensuring that the solution meets the requirements and addresses the process safety risks.
Training and Development
• Provide inputs to the development and review of the annual training program comprising Process Safety topics (e.g. PHA participants training, PHA leaders training, Sulfonation, Reactive Chemistry, etc.).
• Act as trainer and support the execution of the training program.
Incident Investigation
• Lead incident investigations for Type III Process Safety Incidents or Types I and II incidents with high potential or high complexity (per management discretion).
• Ensure that recommendations from Process Safety Incidents are closed timely and the resolution reduces process safety risks.
• Review Process Safety Incidents investigations to ensure thoroughness in the identification of root causes adequacy of recommendations to prevent reoccurrence. 
• Make a critical evaluation of common causes of Process Safety Incidents and propose solutions to address them.
Risk Assessment
• Perform quality check on PHAs led by others ensuring comprehensiveness, solid basis, and adherence to CORP-32 – Process Hazards Analysis Standard and good practices related to the execution of PHAs (Hazop and LOPA).
• Participate in PHAs for processes where Stepan Critical materials are used.
• Liaise with contractors specialized in Quantitative Risk Assessments and support the definition of the basis for the assessment.
• Promote the use of CORP-54 - EHS&S Risk Identification and Assessment to ensure proper communication of risks throughout the organization.
Continuous Improvement
• Promote a culture of continuous improvement in process safety performance.
• Review the scope of Capital Projects to ensure compliance with RAGAGEPS, Stepan and legal requirements. 
• Provide support in the elaboration of Capital Project scopes with focus in Process Safety. Ensure that projects have solid basis of design.

Qualifications

Minimum of 5 years of experience as process engineer and a minimum of 5 years of experience leading process safety management, in chemical, refinery or pharmaceutical manufacturing industries. Experience managing process safety across multiple sites, especially overseas and Fire Protection Systems is a plus.
•    Additional experience required: 
o    Hazop leadership and LOPA participation
o    Electrical Classification for Hazardous Locations
o    Participation in Dust Hazards Analysis (DHA)
o    Reactive chemistry and definition of basis of emergency venting sizing
o    Flammables and Combustible Dusts Safety
o    Incident Investigation techniques
o    PSM Auditing process minimally as an auditor
o    Regulatory aspects of OSHA PSM and EPA RMP
o    RAGAGEPS such as API and NFPA standards
o    Trainer in Process Engineering or Process Safety matters
•    Additional experience desired (plus):
o    LOPA leadership.
o    Safety Instrumented Systems (SIS)
o    Facility Siting and Human Factors Assessments
o    CCPS Risk Based Process Safety (elements implementation, system management)    
•    Certifications: Certified Process Safety Professional (CPSP) or similar certifications preferred.

Education

Bachelor’s degree in chemical engineering, Process Engineering, or a related field. Master’s degree preferred.

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