Process Safety Engineer

Process Safety Engineer

Research Triangle Park, NC

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence and Transparency. As a Process Safety Engineer you will be responsible for developing, implementing, and maintaining the organization's Process Safety Management (PSM) programs to ensure safe, compliant, and reliable operations. This role leads cross-functional efforts to identify and control process hazards, reduce operational risk, and promote a strong process safety culture throughout the facility. This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities

• Lead the development, implementation, and continuous improvement of the site's PSM program in accordance with OSHA 29 CFR 1910.119 and EPA RMP requirements.
• Develop, implement, oversee and maintain all PSM program elements, including but not limited to:
• Process Hazard Analyses (PHA) and revalidations
• Management of Change (MOC)
• Pre-Startup Safety Reviews (PSSR)
• Operating procedures and safe work practices
• Mechanical Integrity (MI) and equipment reliability programs
• Incident and near miss investigation and root cause analysis
• Contractor safety and training
• Emergency planning and response
• Facilitate cross-functional HAZOPs, LOPA studies, and risk assessments; ensure findings are tracked and resolved.
• Serve as subject-matter expert for process risk, technical safety standards, and hazard controls.
• Partner with engineering, operations, maintenance, and EHS to evaluate process changes, equipment upgrades, tool changes, and capital projects for safety and regulatory impact.
• Provide technical guidance to engineering and operations teams regarding process safety requirements, regulatory compliance, and risk mitigation strategies.
• Serve as the site authority for Maximum Allowable Quantity (MAQ) determinations per applicable fire codes (IFC/NFPA), internal standards, and any other applicable regulatory requirements.
• Maintain an accurate inventory of hazardous materials by control area, ensuring compliance with MAQs and separation requirements.
• Develop systems for monitoring chemical usage, storage, and movement to proactively prevent MAQ exceedances.
• Review facility modifications, equipment changes, and chemical substitutions for MAQ impact as part of the MOC process.
• Collaborate with Engineering, Operations, Procurement, and Facilities teams to ensure storage rooms, control areas, and fire protection systems meet MAQ‑related design criteria.
• Coordinate with local fire authorities or regulatory agencies when MAQ reporting, permitting, or inspections are required.
• Identify and lead projects required to bring MAQ‑related deficiencies back into compliance (e.g., fire‑rated separation, secondary containment, inventory redistribution).
• Analyze process safety metrics, develop leading and lagging indicators, and provide regular reports to leadership.
• Lead and support process safety audits, inspections, and regulatory reviews; develop improvement plans based on findings.
• Develop and deliver process safety and MAQ training programs for employees and contractors.
• Champion a strong process safety culture through communication, coaching, and visible engagement in the field.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business

Qualifications

• Bachelor's degree in engineering (chemical, mechanical, industrial, or related field preferred) or equivalent experience.
• 5+ years of experience in process safety management.
• Strong knowledge of OSHA PSM, EPA RMP, NFPA, API, and other relevant industry standards.
• Experience conducting PHAs (HAZOP, What-If, FMEA) and risk assessments.
• Strong knowledge of MAQ requirements and management.
• Demonstrated ability to lead cross-functional teams and influence without direct authority.
• Excellent analytical, communication, and problem-solving skills.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• PHA/LOPA leadership certification.
• Experience in chemical, petrochemical, pharmaceutical, or manufacturing environments.
• Knowledge of reliability engineering or mechanical integrity systems.
• Familiarity with software used for PHA, incident investigations, and MOC workflows.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.