Deputy Manager

Educational Qualification: B.E./B.Tech - Chemical Engineering.
Candidates with a specialization or additional qualification in Process Safety / Chemical Safety are preferred. Experience 6- 12 years of experience in Process Safety, Reaction Safety, Process Hazard Analysis, or Process Safety R&D in Pharmaceutical, API, Fine Chemical, Specialty Chemicals
Role Objective
To lead and execute Process Safety Studies, Chemical Reaction Hazard Assessments, Powder Safety Studies and Thermal/Reaction Safety Testing for new and existing processes, ensuring safe scale-up, technology transfer, plant operation and modification.Key Responsibilities1. 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.

2. 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 safe operating limits, critical process parameters, emergency quench requirements and cooling requirements.
• Interpret reaction-safety test data and translate results into plant operating controls.

3. Reaction Calorimetry & Thermal Safety StudiesHands-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.
4. 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.5. 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.

6. 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.