Kelly · 1 day ago
Process Safety Engineer (API Manufacturing)
Petersburg, VA
Full-time
Onsite
Senior Level
$135K/yr - $160K/yr
7+ years expKelly Government Solutions is seeking a Process Safety Engineer to work on-site at Phlow Corp in Petersburg, VA. The role involves building and improving the API Manufacturing Process Safety program, leading safety assessments, and ensuring compliance with safety regulations in a manufacturing environment.
OutsourcingProfessional Services
Hiring Manager
Susan Schechter, PMP
Responsibilities
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, overpressure, 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 GMP Manufacturing Operations, Process Engineering, Quality & Regulatory, Facility Security, and local emergency responders to support drills, pre-incident planning, and safe execution of campaigns
Qualification
Required
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
Demonstrate practical experience with exothermic/reactive chemistry, overpressure 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
Preferred
pharma/API or chemical processing experience highly preferred
Benefits
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)
Company
Kelly
We’ve been helping organizations find the people they need longer than any other company in the world.
10001+ employees
H1B Sponsorship
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2025 (85)
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Funding
Current Stage
Public CompanyTotal Funding
unknown1978-01-13IPO
Leadership Team
Chris Layden
Chief Executive Officer
N
Nicholas Zuhlke
Vice President, Controller, and Chief Accounting Officer
Recent News
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