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Senior Process Safety Engineer Jobs in Raleigh, NC

IQVIA

Safety Associate

Durham, NC

$44K - $112K/yr

... senior operation team members. Essential Functions: * To Prioritize and complete the assigned trainings on time. * Process Safety data according to applicable regulations, guidelines, Standard ...

IQVIA

Safety Associate

Durham, NC

$44K - $112K/yr

... senior operation team members. Essential Functions: * To Prioritize and complete the assigned trainings on time. * Process Safety data according to applicable regulations, guidelines, Standard ...

Linde Group

Plant Engineer

Research Triangle Park, NC · On-site

Responsible for resolving engineering issues with proposals or projects and control the project ... Oversees location Contractor Safety Program and location's Process Safety Mechanical Integrity ...

New

Linde

Plant Engineer

Research Triangle Park, NC · On-site

Responsible for resolving engineering issues with proposals or projects and control the project ... Oversees location Contractor Safety Program and location's Process Safety Mechanical Integrity ...

New

Novo Nordisk

EM/GMP Process Professional II

Clayton, NC · On-site

Serve as a back-up as needed for the Sr Process Professional and as a mentor/coach for junior team ... Follow all safety & environmental requirements in the performance of duties * Other duties as ...

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All JobsProcess Safety Engineer JobsSenior Process Safety Engineer JobsSenior Process Safety Engineer Jobs in Raleigh, NC

Senior Process Safety Engineer information

See Raleigh, NC salary details

$72.9K

$117.7K

$165.7K

How much do senior process safety engineer jobs pay per year?

As of Jul 15, 2026, the average yearly pay for senior process safety engineer in Raleigh, NC is $117,735.00, according to ZipRecruiter salary data. Most workers in this role earn between $101,100.00 and $130,700.00 per year, depending on experience, location, and employer.

What engineers make $300,000 a year?

Senior Process Safety Engineers in the chemical, oil and gas, or pharmaceutical industries can earn $300,000 or more annually, especially with extensive experience, specialized certifications, and leadership roles. High salaries are often associated with seniority, complex projects, and working in high-risk environments that require advanced knowledge of safety protocols and risk management tools.

What are the main challenges a Senior Process Safety Engineer faces when implementing new safety protocols across multiple facilities?

A Senior Process Safety Engineer often encounters challenges such as ensuring consistent application of safety standards across diverse sites, gaining buy-in from cross-functional teams, and adapting protocols to facility-specific hazards. Additionally, balancing regulatory compliance with operational efficiency requires strong communication and project management skills. Successfully addressing these challenges usually involves close collaboration with site managers, operations teams, and regulatory bodies, as well as ongoing training and audits to maintain high safety standards.

What are the key skills and qualifications needed to thrive as a Senior Process Safety Engineer, and why are they important?

To thrive as a Senior Process Safety Engineer, you need a solid background in chemical or process engineering, in-depth knowledge of process safety management (PSM), and typically a bachelor's degree in engineering with relevant certifications like CSP or CCPSC. Familiarity with process hazard analysis (PHA) tools, safety lifecycle software (such as PHA-Pro or BowTieXP), and regulatory standards (OSHA, API) is crucial. Strong analytical thinking, leadership, and effective communication skills help you guide multidisciplinary teams and convey complex safety issues clearly. These competencies are vital to ensure operational safety, regulatory compliance, and the prevention of major incidents in high-risk industrial environments.

What is the highest salary of a safety engineer?

Senior Process Safety Engineers can earn salaries exceeding $150,000 annually, especially with extensive experience, advanced certifications, and working in high-risk industries such as oil and gas or chemical manufacturing. Top earners in this field may reach salaries over $180,000 or more, depending on location and employer size.

What engineer makes $500,000 a year?

Senior Process Safety Engineers in the chemical, oil and gas, or petrochemical industries can earn salaries approaching or exceeding $500,000 annually, especially with extensive experience, specialized certifications, and leadership roles. High compensation often includes bonuses, profit sharing, and other incentives for senior-level professionals managing complex safety systems and compliance.

What engineers make $200,000 a year?

Senior Process Safety Engineers can earn $200,000 or more annually, especially with extensive experience, specialized certifications, and working in high-demand industries like oil and gas or chemical manufacturing. Compensation varies based on location, company size, and individual expertise, often including bonuses and benefits.

What is the difference between Senior Process Safety Engineer vs Process Safety Engineer?

AspectSenior Process Safety EngineerProcess Safety Engineer
CertificationsTypically holds API, NEBOSH, or equivalent certificationsOften requires similar certifications, but less experience needed
Work EnvironmentLeads safety projects, mentors junior staff, and manages complex risk assessmentsSupports safety initiatives, conducts hazard analyses, and assists in safety documentation
Employer & Industry UsageCommon in oil & gas, chemical, and refining industriesUsed across similar industries, often as entry to mid-level role

The main difference between a Senior Process Safety Engineer and a Process Safety Engineer lies in experience, leadership responsibilities, and project scope. Senior professionals typically lead safety initiatives and mentor others, while Process Safety Engineers focus on supporting safety tasks and analysis. Both roles are vital for maintaining safety standards in high-risk industries.

What does a Senior Process Safety Engineer do?

A Senior Process Safety Engineer is responsible for ensuring that industrial processes, especially those involving hazardous materials, are designed and operated safely to prevent accidents and minimize risks. They analyze operations, conduct safety assessments, and implement systems to comply with safety regulations. Additionally, they lead incident investigations, develop safety procedures, and provide technical guidance to engineering teams to promote a strong safety culture within the organization.
What are the most commonly searched types of Process Safety Engineer jobs in Raleigh, NC? The most popular types of Process Safety Engineer jobs in Raleigh, NC are:
What are popular job titles related to Senior Process Safety Engineer jobs in Raleigh, NC? For Senior Process Safety Engineer jobs in Raleigh, NC, the most frequently searched job titles are:
What job categories do people searching Senior Process Safety Engineer jobs in Raleigh, NC look for? The top searched job categories for Senior Process Safety Engineer jobs in Raleigh, NC are:
What cities near Raleigh, NC are hiring for Senior Process Safety Engineer jobs? Cities near Raleigh, NC with the most Senior Process Safety Engineer job openings:
Senior Process Safety Engineer jobs near you

Senior Machining Process Engineer - R&D

Vulcan Elements

Durham, NC • On-site

$100K - $130K/yr

Full-time

Posted 7 days ago

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.

Sintered NdFeB magnets are a challenge to machine and finish: hard, brittle, chip-prone, corrosion-sensitive. As a Machining Process Engineer you will own the key performance indicators for machining and finishing processes that turn sintered magnet blocks into finished coating-ready parts. You will evaluate and optimize machining pathways, including wire sawing, precision grinding, tumbling, and other processes.

The ideal candidate is a hands-on abrasive machining expert who can also make a detailed and quantitative process flow diagram. You will improve existing machining methods, including slicing, grinding, chamfering, and surface prep. You will select and qualify new shaping processes from lab-scale development to validated, documented production handoff.

Responsibilities

Process Characterization, Metrology & Quality

    • Metrology, surface finish, and inspection methods
    • Establish SPC and capability baselines and drive loss/defect rates down with data

Equipment Specification & New Process Introduction (NPI)

    • Evaluate, specify, and justify new machining and finishing processes to Vulcan; run vendor trials, define acceptance criteria.
    • Document developed processes and hand off validated, capable processes to pilot production — including processes destined for future high-volume magnet factory programs.

Optimization of Existing Machining Processes

    • Develop and optimize slicing, grinding, abrasive, tumbling processes
    • Minimize loss and maximize material yield while holding thickness tolerance, TTV, bow, and warp targets; quantify the yield-vs-throughput trade space for varying magnet geometries.
    • Development of novel tooling and fixturing as needed
    • Understand and quantify surface effects on downstream coating adhesion, corrosion, and magnetic performance.

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

We are looking for depth in abrasive machining plus the range to own everything around it:

  • Abrasive Machining of Hard/Brittle Materials: Direct experience machining sintered magnets, technical ceramics, carbide, glass, silicon/semiconductor wafers, or similar brittle materials.
  • Diamond Tooling: Working knowledge of diamond wire, wheel, and media specification.
  • Machine Craft: Comfortable at the machine: setup, alignment, fixturing, troubleshooting vibration and chatter.
  • Coolant & Filtration Systems: Practical understanding of coolant chemistry, delivery, filtration technologies, and swarf/sludge handling.
  • Statistics & DOE: Fluency in designed experiments, measurement system analysis, SPC, and capability studies.
  • Metrology & GD&T: Strong command of GD&T interpretation and precision dimensional/surface metrology at micron scale.
  • CAD & Fixture Design: Able to design and iterate workholding, carriers, and handling fixtures (SolidWorks, Fusion 360, or similar).

Qualifications

  • B.S. in Mechanical Engineering, Manufacturing Engineering, Materials Science, or equivalent hands-on experience.
  • 5+ years of process engineering experience in machining/finishing.
  • Demonstrated ownership of a machining process from development through production release.
  • Experience with NdFeB or other permanent magnet materials is a strong plus, but we will gladly teach magnets to someone who deeply knows grinding.

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

Desired Skills

  • Experience in semiconductor wafering, optics fabrication, cutting tool manufacturing, or technical ceramics.