Design Lead Engineer

Process Alliance LLC; Richmond (VA); On-site; USD 120,000 - 180,000; Full time

Job summary

Process Alliance LLC in the United States is seeking a Design Lead Engineer to provide technical leadership across all phases of process design for major capital projects. The role focuses on pharmaceutical, fine chemical, or other highly regulated sectors, guiding FEED through detailed design with SME coaching.

You will oversee PFDs, P&IDs, utility studies, and equipment sizing, and mentor engineering teams while ensuring compliance with industry standards.

Qualifications

• Bachelor or higher in Chemical or Mechanical Engineering.
• 5+ years progressively responsible process design experience.
• Strong knowledge of PFDs, P&IDs, mass balances, and pump hydraulics.
• Hands-on experience with pressure relief device design, control valve sizing, and scenario analysis.
• Experience on capital projects in an EPC or similar design organization.
• Life Sciences industry experience.

Responsibilities

• Lead development of process engineering deliverables across all project phases.
• Oversee development of PFDs, P&IDs, utility summaries, equipment specs, and line lists.
• Coordinate issue resolution between owners and design engineers.
• Provide technical oversight, mentorship, and backchecking of engineering work.
• Review process design calculations for appropriateness, including mass balances and hydraulics.
• Ensure sizing of pressure relief devices, instruments, and control valves.
• Prepare process scopes, design basis documents, and utility studies.
• Review vendor data and integrate into design packages.
• Lead development of project schedules and budgets and manage to goals.
• Ensure compliance with codes, standards, and regulatory requirements.

Skills

Process design

PFDs & P&IDs

Mass balances

Pump hydraulics

Scenario analysis

Leadership

Education

Chemical Engineering (BS/MS)

Tools

Aspen Plus

HYSYS

Pipe-Flo

Job description

Process Alliance is a leading engineering consultancy firm dedicated to delivering innovative solutions in engineering, automation, manufacturing services, and medical devices. With a commitment to being a better model of problem solving, we have been at the forefront of providing cutting-edge engineering services to clients across the life science industry. Our team of experts thrives on solving complex challenges and driving technological advancements to meet the evolving needs of our clients.

Position Overview

We are seeking an experienced Design Lead Engineer to provide technical leadership and SME-level coaching on all phases of process design for major capital projects. This role will be responsible for guiding execution of all project phases from Front End Engineering Development (FEED) through the development of detailed design packages. The ideal candidate has deep experience in process design; specifically, pharmaceuticals, fine chemicals, or other highly regulated industries.

Responsibilities

• Lead the development of process engineering deliverables across all project phases.


• Oversee development of PFDs, P&IDs, utility summaries, equipment specifications, and line lists.


• Coordinate issues resolution between owners and design engineers.


• Provide technical oversight, mentorship, and backchecking of engineering work.


• Review process design calculations for appropriateness, including mass balances, pump hydraulics, line sizing, and equipment sizing.


• Ensue proper sizing of pressure safety devices, instruments, and control valves.


• Prepare process scopes, design basis documents, and utility studies to ensure safe, efficient, and cost-effective facilities.


• Review vendor data and integrate into overall design packages.


• Lead development of project schedules and effort-hour budgets and manage to meet project goals.


• Ensure compliance with applicable codes, standards, and regulatory requirements.

Qualifications

• BS or MS in Chemical Engineering or Mechanical Engineering.


• 5+ years of progressive process/design engineering experience.


• Strong knowledge of PFDs, P&IDs, mass balances, and pump hydraulics.


• Hands-on experience with pressure relief device design, control valve sizing, and scenario analysis.


• Experience working on capital projects in a process engineering capacity with an Engineering, Procurement, and Construction (EPC) firm or similar design engineering organization.


• Industry experience in Life Sciences.

Preferred Qualifications

• Pharmaceutical or fine chemical industry experience.


• Proficiency with process simulation tools (Aspen Plus, HYSYS).


• Familiarity with hydraulic sizing tools such as Pipe-Flo.


• Demonstrated leadership in training and developing engineering teams

Qualified applicants must be authorized to work in the United States on a full-time basis. Process Alliance will not provide support for or sponsor work authorization or visas for this role, including but not limited to F-1 CPT, F-1 OPT, F-1 STEM OPT, J-1, H-1B, TN, O-1, E-3, H-1B1, or L

About Our Culture

At Process Alliance, we strive to be a better model for how problems are solved, and solutions are delivered. We believe in providing a supportive and inclusive work environment where employees can thrive both personally and professionally. Join our team and be part of a company that is shaping the future of engineering solutions.

Learn more about us:

Visit our website at www.processalliance.com to explore our projects, expertise, and the impact we make in the engineering and consultancy space. Process Alliance is an equal opportunity employer. We encourage applications from candidates of all backgrounds and experiences.