Roles and Responsibilities:

1. Process Safety Studies

- Lead and participate in PHA, HAZOP, HAZID, What-If, LOPA and Risk Assessment studies.
- Prepare Process Safety Assessment Reports for new products, existing processes, scale-up and technology transfer.
- Review PFDs, P&IDs;, process descriptions, operating procedures and process parameters.
- Identify fire, explosion, toxic-release, overpressure, chemical-reactivity and thermal-runaway hazards.
- Define appropriate preventive and mitigative safeguards.
- Support MOC and PSSR activities.

1. Chemical Reaction Safety

- Conduct preliminary and detailed Chemical Reaction Hazard Assessments.
- Evaluate exothermic reactions, decomposition reactions, gas generation, accumulation and thermal runaway.
- Assess reaction hazards during scale-up, process development and technology transfer.
- Establish secure operating limits, critical process parameters, emergency quench requirements and cooling requirements.
- Interpret reaction-safety test data and translate results into plant operating controls.

1. Reaction Calorimetry & Thermal Safety Studies

Hands-on experience by technical understanding & Interpretation in the process:
- RC / RC1 / Reaction Calorimetry
- ARC – Accelerating Rate Calorimetry
- ARSST – Advanced Reactive System Screening Tool
- DSC – Differential Scanning Calorimetry
- TSU – Thermal Screening Unit
- RSD – Rapid Screening Device
- TGA / Thermogravimetric Analysis
- Thermal stability and decomposition studies
- Adiabatic / runaway reaction assessment
- Gas-generation and pressure-rise studies

Current pharma/API process-safety roles specifically mention DSC, RC, ARC, TSU and ARSST testing.
1.



Powder Safety Studies

- Conduct/review powder and combustible-dust hazard assessments.

- Evaluate
- Pmax – Maximum Explosion Pressure
- Kst – Deflagration Index
- MIE – Minimum Ignition Energy
- MEC – Minimum Explosible Concentration
- MIT – Minimum Ignition Temperature

- Dust explosibility
- Dust-layer ignition
- Powder resistivity / electrostatic hazards

- Combustibility and explosion severity
- Assess hazards associated with milling, sieving, drying, charging, discharging and powder handling.
- Recommend explosion prevention, protection, isolation and mitigation measures.

Powder safety, static electricity, dust explosion, MIE and related testing are explicitly included in current pharma/chemical Process Safety Engineer profiles.
1. Explosion & Relief-System Safety

- Review PSV, rupture disc and emergency relief requirements.
- Assess runaway reaction, fire exposure, blocked outlet and gas-generation scenarios.
- Perform/review pressure relief and venting assessments.
- Conduct or coordinate explosion vent sizing.
- Review explosion protection, suppression and isolation requirements.
- Assess pressure/explosion hazards associated with reactors, dryers, filters, mills and powder-handling systems.

1. Process Hazard Analysis





- Facilitate/participate in:

- HAZOP

- HAZID
- What-If Analysis

- LOPA

- PHA

- QRA
- SIL assessment, where applicable
- FMEA/FTA/ETA, where applicable
- Ensure recommendations are technically evaluated and closed effectively.

1. Incident & Risk Management

- Investigate process-safety incidents, near misses and deviations.
- Conduct Root Cause Analysis (RCA).
- Identify corrective and preventive actions.
- Monitor process-safety recommendations and action closure.
- Develop process-safety KPIs and improvement plans.

Essential Technical Competencies Chemical Engineering | Process Safety | Reaction Safety | HAZOP | HAZID | PHA | LOPA | QRA | MOC | PSSR | Reaction Calorimetry | RC/RC1 | ARC | ARSST | DSC | TSU | RSD | TGA | Thermal Runaway | Chemical Reaction Hazard Assessment | Powder Safety | Dust Explosion | Pmax | Kst | MIE | MEC | MIT | Static Electricity | Explosion Vent Sizing | PSV | Rupture Disc | Relief System | Risk Assessment | RCA

Preferred Industry Experience

- Pharmaceutical / API manufacturing
- Fine chemicals
- Specialty chemicals
- Agrochemicals
- Chemical manufacturing

Job Requirements :

- 5-15 years of experience in Process Safety Engineering or related field.
- B.E./B.Tech/M.E./M.Tech Chemical Engineer with 6–12 years of experience in Process Safety, preferably in Pharma/API or Chemical manufacturing
- Strong hands-on exposure to HAZOP/PHA/LOPA, Chemical Reaction Hazard Assessment, RC/ARC/ARSST/DSC/TSU testing, Powder Safety, Dust Explosion Assessment, Relief Systems and Process Safety Risk Assessment.

📌 Process Safety Engineer (Hyderabad)
🏢 Honour Lab
📍 Hyderabad