Process Safety Engineer

About the role

Vulcan Elements is committed to the production of American-made rare-earth permanent magnets, which play a crucial role in bolstering national security and supporting economic stability. Our focus spans essential industries such as defense, aerospace, and automotive, as we aim to foster a future driven by advanced technology. In the capacity of a Process Safety Engineer, your primary responsibility will be to design, implement, and sustain our Process Safety Management (PSM) programs, ensuring that our operations are not only safe but also compliant and efficient. Initially, this position will be located in Durham, NC, and will transition to Benson, NC once our new facility is operational.

Key facts

What you'll do

• Lead the development, implementation, and continuous improvement of the PSM program, ensuring adherence to OSHA 29 CFR 1910.119 and EPA RMP regulations.
• Manage all aspects of the PSM program, which includes conducting Process Hazard Analyses (PHA) and revalidations, overseeing Management of Change (MOC) processes, and facilitating Pre-Startup Safety Reviews (PSSR).
• Create and maintain operational procedures, mechanical integrity programs, and protocols for incident investigations, contractor safety, and emergency response planning.
• Conduct HAZOPs, LOPA studies, and comprehensive risk assessments, ensuring that any identified issues are tracked and effectively addressed.
• Serve as the go-to expert on process risk and safety standards, working closely with engineering, operations, maintenance, and EHS teams to evaluate the safety implications of process modifications and equipment upgrades.
• Provide technical guidance to various teams regarding compliance with process safety regulations and strategies for risk mitigation.
• Establish systems to monitor chemical usage and storage, ensuring compliance with Maximum Allowable Quantity (MAQ) requirements according to fire codes and internal policies.
• Review modifications to facilities and chemical substitutions for their implications on MAQ as part of the MOC process.
• Collaborate with different teams to ensure that MAQ-related design criteria for storage areas and fire protection systems are met.
• Liaise with local fire authorities concerning MAQ reporting and inspections.
• Identify and spearhead initiatives to resolve compliance issues related to MAQ.
• Analyze metrics related to process safety and provide regular updates to the leadership team.
• Conduct audits of process safety and regulatory compliance, developing improvement plans based on audit findings.
• Design and deliver training sessions focused on process safety and MAQ for both employees and contractors.
• Foster a robust process safety culture through effective communication and active field engagement.

Requirements

• A Bachelor's degree in engineering (chemical, mechanical, industrial, or a related field) or equivalent professional experience.
• A minimum of 5 years of experience in the field of process safety management.
• Comprehensive knowledge of OSHA PSM, EPA RMP, NFPA, API, and other pertinent industry standards.
• Demonstrated experience in executing PHAs (HAZOP, What-If, FMEA) and conducting risk assessments.
• Strong familiarity with MAQ requirements and their management.
• Capability to lead cross-functional teams and influence stakeholders without direct authority.
• Exceptional analytical, communication, and problem-solving skills.

Nice to have

• Certification in PHA/LOPA leadership is a plus.
• Experience in the chemical, petrochemical, pharmaceutical, or manufacturing industries.
• Understanding of reliability engineering or mechanical integrity systems.
• Familiarity with software tools designed for PHA, incident investigations, and MOC workflows.

Skills & tools

• Proficient in safety management systems and regulatory compliance standards.
• Knowledgeable in risk assessment methodologies and safety training programs.

Practical notes

• Applicants must be U.S. Persons due to the requirement of accessing U.S. export-controlled information or facilities.
• The role necessitates regular presence on the production floor, which includes the ability to navigate various facility areas, climb stairs, and work in environments that may be hot, humid, or noisy.
• Personal protective equipment, including respirators, is mandatory, and strict adherence to safety policies and regulations is required. Candidates will need to complete fit testing and wear appropriate PPE during their tasks.