Senior Process Engineer

Worley is seeking a Senior Process Engineer to support our Chemicals business line. In this role, you will provide process engineering services to Worley and its customers while delivering technical leadership, mentorship, and project execution expertise for chemical industry projects. You’ll play a key role in supporting projects across specialty chemicals, petrochemicals, and related industries, ensuring safe, efficient, and cost-effective solutions.

Process Engineering Delivery

• Provide technical support during commissioning, startup, and troubleshooting of chemical process units.
• Process Flow Diagrams (PFDs)
• Maintain Management of Change (MoC) logs and secure client approvals.
• Support process optimization, yield improvement, and scaleup for chemical manufacturing.
• Process safety studies, process basis of design documents, and technical reports
• Apply knowledge of chemical reaction engineering, thermodynamics, separations, and material balances to design safe and efficient systems.
• Review and comment on interdisciplinary deliverables (piping layouts, isometrics, 3D models, mechanical equipment specifications, etc.).
• Communicate project resource needs and coordinate with the Process Engineering Manager.
• Assign tasks, provide oversight, and mentor junior and midlevel engineers.
• Contribute to team knowledge sharing, training, and mentoring.
• Support procurement, construction, and commissioning activities.
• Define scope of work, prepare proposals, and develop cost estimates.
• Participate in PHA, HAZOP, and LOPA for chemicals projects as a technical expert.
• Stay current with developments in chemical process technologies and industry best practices.
• Incorporate environmental, health, and safety (EHS) considerations into designs, with an emphasis on OSHA, EPA, and international regulations.
• Serve as the senior process engineer on chemicals projects, reporting to the Process Engineering Manager.
• Proactively resolve issues and discrepancies with clients.
• Help strengthen Worley’s reputation as a trusted chemicals project partner.
• Deliver engineering services that meet Worley, client, and regulatory requirements—on time and within budget.
• Support project execution strategies tailored to the chemicals industry, including revamps, expansions, debottlenecking, and grassroots projects.
• Provide updates on budget, schedule, and progress to stakeholders.
• Own, develop, check, and approve key process engineering deliverables, including:Process Flow Diagrams (PFDs)Heat & Material Balances (HMBs)Piping & Instrumentation Diagrams (P&IDs)Process models (Aspen Plus®, HYSYS®, OLI Flowsheet, UniSim, Aveva Process Simulation™)Equipment and line sizing for specialty chemical processes (reactors, distillation, separations, utilities, etc.)Relief system (flare) evaluation, PRS overpressure analysis, and OSHA documentation (API SCPRS 520/521/526/2000)Process safety studies, process basis of design documents, and technical reports

On-site at our Charleston, WV office. This position is open only to individuals who are legally authorized to work in the United States. Sponsorship for employment visas, now or in the future, is not available for this position.

• Knowledge of chemical process safety, EHS regulations, and applicable local/international standards.
• Strong background in multidisciplinary projects and teamwork.
• Relief system (flare) evaluation, PRS overpressure analysis, and OSHA documentation (API SCPRS 520/521/526/2000)
• Flow Modeling: AFT Suite (Fathom, Arrow, Impulse), Korf, PipeFlo
• Heat Exchanger Sizing: HTRI Xchanger Suite, UniSim Heat Exchangers
• Proven ability to lead process engineering for multiple chemical industry projects simultaneously.
• Simulation: Aspen Plus®, HYSYS®, OLI Flowsheet, UniSim, Aveva Process Simulation™
• Piping & Instrumentation Diagrams (P&IDs)
• Process models (Aspen Plus®, HYSYS®, OLI Flowsheet, UniSim, Aveva Process Simulation™)
• Flare Header Evaluations: Aspen Flare System Analyzer™, UniSim Flare
• Proficiency in process engineering software, including:Simulation: Aspen Plus®, HYSYS®, OLI Flowsheet, UniSim, Aveva Process Simulation™Flare Header Evaluations: Aspen Flare System Analyzer™, UniSim FlareHeat Exchanger Sizing: HTRI Xchanger Suite, UniSim Heat ExchangersFlow Modeling: AFT Suite (Fathom, Arrow, Impulse), Korf, PipeFloOther: Internal/external calculation tools and MS Office Suite
• Advanced technical and practical skills with a track record of delivering accurate, highquality work in chemicals.
• Equipment and line sizing for specialty chemical processes (reactors, distillation, separations, utilities, etc.)