Engineer, Sr. Process Design

pbfenergy; Oregon (OH); On-site; USD 120,000 - 160,000; Full time

Job summary

PBF Energy is seeking a Senior Process Design Engineer to lead process engineering design and project support across refinery units, from concept through commissioning. You will own the relief valve and flare system programs, perform sizing and calculations, maintain PSPPM data, and drive process safety, optimization, and capital project execution.

Collaborate with operations, maintenance, and safety teams; mentor junior engineers and utilize tools like PI System, Seeq, and HYSYS to model and

Qualifications

• B.S. in Chemical Engineering required.
• 5+ years of petrochemical/process design experience required.
• Experience in refinery/chemical plant project development.
• Experience with HYSYS or similar process design software.
• PSPPM or PSV sizing software experience preferred.

Responsibilities

• Support project development from inception to funding approval, aligning with engineering standards and best practices.
• Own and manage site's relief valve and flare systems; perform sizing, calculations and PSPPM data upkeep.
• Perform equipment sizing, PFDs/P&IDs development, and process optimization.
• Ensure designs comply with safety, environmental and cost standards and company practices.
• Support project commissioning, startup activities, and field coordination.

Skills

Process design

Project development

Collaboration

Mentoring

Troubleshooting

Education

B.S. in Chemical Engineering

Tools

HYSYS

Aspen HYSYS

PI System

Seeq

PSPPM

Job description

Engineer, Sr. Process Design

The Process Design Engineer provides process engineering design and project support for multidisciplinary projects across all units within the refinery; managing project concepts from inception to capital funding approval and through commissioning. As a member of the Process Engineering team, the Process Design Engineer supports the Capital Projects group in developing and guiding process and project design. Additionally, this role will own the sites relief valve and flare system programs, including the sizing, validation and mitigation plans. Other duties may include supporting unit troubleshooting, identifying and implementing process improvements, supporting site safety and environmental groups, and may assume additional process engineering responsibilities as needed.

RESPONSIBILITIES:

• 1. Project Development:
  • Support the Project Team with project engineering requirements, including process design input, technical reviews, scope definition, and alignment with engineering standards and best practices.
  • Identify and evaluate capital and optimization projects aligned with safety, environmental, and economic goals and standards.
  • Collaborate with business team, technical, and project teams resources to advance initiatives.
  • Issue Requests for Proposals to outside companies in support of completing process engineering studies. Evaluate proposals and manage studies conducted by outside engineering firms.
• 2. Relief Valve and Flare system:
  • Act as owner and SME for site's relief valve and flare systems. Preforming all required calculations to support day-to-day operation as well as project development.
  • Maintain the refinery PSV database, relief scenarios, calculations, documentation, and inspection/maintenance requirements.
  • Perform relief valve sizing, relief system calculations, and maintain the PSPPM database.
  • Develop and implement mitigation plans for PSV maintenance and inspection.
• 3. Process Design, Engineering & Optimization:
  • Perform equipment sizing and specification (pumps, heat exchangers, columns, reactors, piping, etc.).
  • Evaluate existing processes for performance improvements, yield enhancement, energy efficiency, and operating cost reductions.
  • Support Front-End Engineering Design (FEED) and detailed engineering phases.
  • Develop and optimize process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and heat and material balances.
• 4. Standards Compliance & Process Safety:

  Review project designs addressing process design, safety, environmental compliance, reliability, operability, constructability, and cost estimation.

  Ensure project development complies with PBF's capital project best practices, industry design standards, and site-specific requirements.

  Demonstrate knowledge of all safety, health and environmental issues that impact the refinery and personnel to ensure the project design considers safety and environmental potential impacts. Adhere to all applicable legislation, regulations, codes, and standards.

  Take action to address safety/environmental concerns and mitigate risks.

  Share results of safety/environmental impact assessments with decision-makers.

  Support the Process Hazards Analysis process for new projects and Unit Revalidations.

• 5. Execution Support & Field Coordination:
  • Support project commissioning and startup including equipment inspection, operating procedure updates and development, training, startup assistance and project post-audit.
• 6. Collaboration, Mentoring & Knowledge Sharing:
  • Mentor process engineers in areas of expertise
  • Collaborate with operations, maintenance, reliability, safety, and environmental teams to ensure effective and compliant process designs.
  • Collaborates with the Process Engineering Leads as needed to support technical tasks.
  • Participate in PBF corporate and/or TRC special project teams, initiatives and Turnarounds as assigned.
• 7. Digital Tools & Communication:
  • Utilize digital tools (e.g., PI System, Seeq, HYSYS) for process troubleshooting, and optimization.
  • Support and contribute to process modeling efforts, collaborating with the process engineering team to optimize and troubleshoot refinery operations.
  • Prepare technical reports, documentation, and presentations to communicate project progress and recommendations.
  • Utilize Aspen HYSYS (and other applicable simulation tools) to develop, tune, and maintain rigorous process models that enable unit optimization, troubleshooting, constraint identification, debottlenecking, evaluation of operational changes and capital projects, including support for design basis development and engineering studies.

JOB QUALIFICATIONS:

• B.S. in Chemical Engineering.
• 5+ years of relevant petro chemical experience required, with some process design experience preferred.
• Project development experience in a refinery and/or chemical plant environment is required.
• Experience in using HYSYS or other process design software required.
• PSPPM or other PSV sizing software experience preferred.
• De