Process Safety Engineer; API Manufacturing

Process Safety Engineer (API Manufacturing)

Kelly Government Solutions has a full-time direct hire opportunity to work on-site at Phlow Corp as a Process Safety Engineer (API Manufacturing) on the Petersburg, VA campus.

$/yr - $/yr

• Competitive compensation, annual bonus program, and comprehensive benefit package
• 100% employer‑paid health, vision, and dental plans
• Paid leave and company holidays
• 401(k) plan with 6% company match
• Opportunity for reimbursement of relocation expenses (if applicable)

• Build the API Manufacturing Process Safety program from the ground up for small‑molecule API manufacturing
• Build, implement, and continually improve the API Process Safety program in alignment with OSHA PSM, EPA requirements, and Phlow procedures
• Responsible for the process safety activities associated with technology transfer, process design, and GMP startup
• Lead process safety assessments, Management of Change (MOC), and the implementation and verification of safeguards in GMP manufacturing
• Lead PFMEAs, PHAs, and PSSRs for new and existing API processes; translate outcomes into practical engineered and administrative controls for GMP operations
• Identify and control hazards typical to API operations (e.g., exotherms, over pressure, vacuum collapse, flammable/toxic releases, static, dust deflagration) and ensure safeguards are in place and effective
• Coordinate thermal hazard characterization (e.g., DSC/ARC/RC1) and ensure data are integrated into equipment design, operating limits, automation strategies, interlocks, and procedures
• Develop and support relief and vent strategies (PSVs/rupture discs, vent sizing, scrubbers/containment) and contribute to LOPA/SIL evaluations and verification of assumptions
• Own the process safety portion of the MOC process by evaluating risk impacts, defining required safeguards, and confirming PSI updates, training, and startup readiness
• Define mechanical integrity expectations for critical protective systems and instrumented functions; work closely with Maintenance and Engineering to prioritize and validate testing
• Develop and deliver training and coaching for employees and contractors on process safety and life safety requirements related to API manufacturing
• Collaborate with Tech Transfer, GMP Manufacturing Operations, Process Engineering, Quality & Regulatory, Facility Security, and local emergency responders to support drills, pre‑incident planning, and safe execution of campaigns

• Bachelor’s degree in Chemical Engineering or a closely related scientific or engineering discipline
• Minimum of seven (7) years of experience that includes process safety, chemical engineering, or EHS in a manufacturing capacity; pharma/API or chemical processing experience highly preferred
• Practical experience with exothermic/reactive chemistry, over pressure protection, or cryogenic/flammable systems
• Working knowledge of OSHA/EPA regulations and core PSM elements (PHA/HAZOP, LOPA/SIL concepts, MOC, PSSR, incident investigation)
• Proficiency with process safety tools and documentation (PSI, risk assessments, action tracking)
• Ability to work in GMP manufacturing suites, technical areas, and utilities with potential exposure to chemical materials, elevated noise, and high awareness for personnel and equipment safety

• Seniority level:
  Mid‑Senior level
• Employment type:
  
  Full‑time
• Job function:
  Engineering and Manufacturing
• Industry: Pharmaceutical Manufacturing