Process Safety Engineer
10 days ago
Durham
Job Description 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. 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. 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. 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.