API Process Safety Engineer for GMP Startup & PFMEA Lead

Phlow Corporation; Petersburg (VA); On-site; USD 100,000 - 150,000; Full time

Job summary

Phlow Corp in Petersburg, VA seeks an API Manufacturing Process Safety Engineer to own and build the API process safety program from the ground up for small-molecule API manufacturing on the Petersburg campus. You will lead process safety activities across tech transfer and GMP operations to ensure safe, compliant, and reliable campaigns.

Responsibilities include PFMEAs, PHAs, PSSRs, MOC, and development of safeguards; experience with exotherms, overpressure, and cryogenic/flammable systems is

Qualifications

• Bachelor’s degree in Chemical Engineering or closely related engineering discipline.
• Experience in process safety, chemical engineering, or EHS in manufacturing (pharma/API or chemical processing preferred).
• Proficiency with process safety tools and documentation (PSI, risk assessments, action tracking).
• Strong analytical and problem-solving skills with the ability to collaborate in cross-functional teams.

Responsibilities

• Build, implement, and continually improve the API Process Safety program in alignment with OSHA PSM, EPA requirements, and Phlow procedures.
• Own and 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... 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.
• Lead or participate in incident and near-miss investigations related to process and equipment; perform root cause analysis and track corrective/preventive actions to closure.
• Develop and deliver training and coaching for employees and contractors on process safety and life safety requirements related to API manufacturing.
• Collaborate closely 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.

Skills

Process Safety

Chemical Engineering

Cross-functional collaboration

Risk Assessment

Root Cause Analysis

Education

Bachelor’s degree in Chemical Engineering

Tools

PSI

PHA/HAZOP

LOPA/SIL

MOC

PSSR

Incident Investigation

Job description

Phlow Corp in Petersburg, VA seeks an API Manufacturing Process Safety Engineer to own and build the API process safety program from the ground up for small-molecule API manufacturing on the Petersburg campus. You will lead process safety activities across tech transfer and GMP operations to ensure safe, compliant, and reliable campaigns.

Responsibilities include PFMEAs, PHAs, PSSRs, MOC, and development of safeguards; experience with exotherms, overpressure, and cryogenic/flammable systems is