Senior Director - Process Safety
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Key skills for this role
About the Role
Emirates Global Aluminium (EGA) is seeking a Senior Director of Process Safety to prevent catastrophic events in aluminium smelting operations. This role establishes major hazard governance, critical control management, and board-level reporting.
Key Skills for This Role
Responsibilities
- Establish and maintain an enterprise wide Major Hazard Risk Management Framework.
- Define, implement, and oversee Critical Controls for major hazard exposures.
- Lead the strategic shift from traditional lagging safety metrics toward Serious Injury and Fatality (SIF) prevention.
- Provide governance and oversight of engineering systems that protect against major hazards.
- Lead the integration of advanced technologies to strengthen process safety performance.
- Provide quarterly Board level reporting on key process safety and major hazard indicators.
Requirements
- Engineering degree (Chemical, Mechanical, Electrical, or Process).
- 15+ years in high hazard industrial operations.
- Deep expertise in HAZOP / LOPA / Bowtie.
- Deep expertise in Critical Control Management.
- Deep expertise in Major Accident Prevention.
- Experience engaging regulators and Board committees.
- Strong digital and data analytics literacy.
Full Job Posting
Job Purpose
- The Process Safety Director is accountable for preventing catastrophic events, including molten metal explosions, high energy electrical incidents, structural failures, toxic gas releases, and major fires.
- The role ensures that major hazard risks are systematically identified, controlled, verified, and reported to Executive Management and the Board.
- This position safeguards people, assets, reputation, and business continuity by strengthening governance, assurance, and operational discipline across all major hazard activities.
Strategic Accountabilities
- Establish and maintain an enterprise wide Major Hazard Risk Management Framework.
- Define, implement, and oversee Critical Controls for major hazard exposures including molten metal handling, potline integrity, gas systems, pressure systems, and confined space entry.
- Ensure governance and control frameworks are aligned with recognized international standards.
- Lead the strategic shift from traditional lagging safety metrics toward Serious Injury and Fatality (SIF) prevention.
- Establish and govern a robust SIF and High Potential (HiPo) Event Framework.
- Monitor and report barrier health and Critical Control effectiveness.
- Ensure all high potential events, critical control failures, and repeated systemic weaknesses are reviewed directly with the committee.
- Implement and oversee an independent verification program for Life Saving Rules and Critical Controls.
- Ensure leadership accountability through structured governance.
- Provide governance and oversight of engineering systems including mechanical integrity, electrical integrity, Management of Change (MOC), and safe design reviews.
- Ensure process safety requirements are embedded into all capital projects.
- Lead the integration of advanced technologies such as AI based predictive analytics, real time monitoring, smart sensors, digital barrier management, and automated shutdowns.
Authority / Decision Making
- Authorized to stop or suspend high risk operations when Critical Controls are not in place.
- Holds decision rights to approve and enforce Critical Control Performance Standards.
- Has authority to require immediate corrective actions.
- Has decision making accountability to approve or reject Management of Change (MOC) outcomes.
- Has the authority to challenge operational decisions and require revalidation of risk assessments.
Qualifications & Skills
- Engineering degree (Chemical, Mechanical, Electrical, or Process).
- 15+ years in high hazard industrial operations.
- Deep expertise in HAZOP / LOPA / Bowtie.
- Deep expertise in Critical Control Management.
- Deep expertise in Major Accident Prevention.
- Experience engaging regulators and Board committees.
- Strong digital and data analytics literacy.
- Demonstrate independent authority and confidence to escalate catastrophic risk concerns.
- Show courage and decisiveness to stop unsafe high risk operations.
- Apply a strong systems thinking mindset.
- Influence senior leadership and operational teams.
Key KPIs (Board Level)
- Zero Tier 1 catastrophic process safety events.
- ≥95% Critical Control Verification effectiveness.
- 100% Management of Change (MOC) compliance for major risk changes.
- Reduction in SIF potential and high potential events.
- Closure of high risk corrective actions within agreed target timeframes.
Why This Role is Critical in Aluminium?
- Aluminium smelting is a high consequence industry involving molten metal above 700°C, high amperage electrical systems, combustible dust exposure, and heavy lifting and crane operations.
- Failure of critical controls can result in multi fatality events, major fires, and significant asset loss.
- This role ensures the organization shifts from reactive injury management to proactive catastrophic risk prevention through strong major hazard governance, critical control assurance, and Board level visibility.
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