Federal Process Engineer

Salas O’Brien, Inc.; Baltimore (MD); Hybrid; USD 95,000 - 115,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

401(k) with company match

Paid time off and holidays

Wellness programs and EAP

Job summary

Salas O’Brien is seeking a Federal Process Engineer to plan, develop, and execute process engineering tasks for industrial, energy, life sciences, and advanced technology projects supporting federal clients.

The role involves developing PFDs, P&IDs, heat/mass balances, and process narratives, while ensuring safety, quality, and regulatory compliance across multidisciplinary teams.

Qualifications

• Bachelor of Science in Chemical/Process/Mechanical/Industrial Engineering or closely related.
• 5–10 years of progressively responsible process engineering experience.
• Experience with federal clients or major defense contractors.
• Experience producing engineering calculations, reports, specifications, and design documents.
• Credentialing such as PE, CCPSC, Six Sigma, PMP, or CAP is preferred.
• Experience working in multidisciplinary teams.

Responsibilities

• Plan, develop, and execute process engineering tasks for industrial and federal projects.
• Develop PFDs, P&IDs, heat and material balances, and process narratives.
• Perform mass and energy balances, hydraulic calculations, and equipment sizing.
• Prepare equipment specs, data sheets, and procurement support.
• Support safety analyses, regulatory compliance, and risk assessments.
• Coordinate with multiple engineering disciplines and project teams.
• Assist with project planning, budgeting, and proposal development.

Skills

Process engineering

Leadership

Team collaboration

Regulatory compliance

MS Office/Calc

AutoCAD/Plant 3D

Education

B.S. in Chemical/Process/Mechanical Eng

Tools

AutoCAD Plant 3D

Bluebeam Revu

Excel

PFD/PID software

Job description

At Salas O’Brien we tell our clients that we’re engineered for impact. This passion for making a difference applies just as much to our team as it does to our projects. That’s why we’re committed to living our values every day: inspiring, achieving, and connecting as shared owners of our success with a focus on a sustainable future.

Building for the long-term means that all of our team members can expect to work on amazing projects with a people-first approach to problem solving. It also means that each member of our team has truly limitless potential to build a unique, meaningful, and high-impact career—and they’ll receive great total rewards along the way.

We are currently working on projects and have openings available to support the modernization of Department of Defense and Department of Energy facilities contributing to the mission of defending the United States and supporting the warfighter.

Job Summary:

The Federal Process Engineer is responsible for planning, developing, and executing process engineering tasks for industrial, manufacturing, energy, life sciences, and advanced technology projects supporting federal clients. Working independently with general supervision, the Federal Process Engineer develops process designs, evaluates existing systems, supports process improvements, and collaborates with multidisciplinary teams to deliver safe, efficient, and compliant engineering solutions.

The Federal Process Engineer will support multiple federal project teams to assess existing industrial processes, introduce commercial technology, and automate process steps to optimize throughput while preserving stringent safety and quality standards.

Duties and Responsibilities:

• Evaluate production, manufacturing, utility, chemical, and industrial processes to improve safety, efficiency, reliability, and sustainability.
• Develop process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), heat and material balances, and process narratives.
• Perform process calculations including mass balances, energy balances, hydraulic calculations, and equipment sizing.
• Prepare equipment specifications, process data sheets, and procurement support documents.
• Support process hazard analyses (PHA), hazard and operational (HAZOP) studies, safety reviews, and regulatory compliance assessments.
• Coordinate with mechanical, electrical, controls, structural, architectural, civil, and environmental disciplines.
• Support facility planning, process layout development, utility coordination, and operational readiness activities.
• Participate in client meetings, technical reviews, and project presentations.
• Support construction, commissioning, startup, and troubleshooting activities.
• Assist with proposal development, scope definition, budgeting, and project planning.
• Mentor junior engineers and provide technical guidance to project team members.

Qualifications and Experience:

• Bachelor of Science degree in Chemical Engineering, Process Engineering, Mechanical Engineering (with significant process engineering experience), industrial engineering (with relevant process experience), or a closely related engineering discipline.
• 5-10 years of progressively responsible process engineering experience.
• Experience supporting industrial, manufacturing, chemical, energy, pharmaceutical, food and beverage, semiconductor, or advanced technology facilities.
• Experience working with federal clients or a major defense contractor.
• Demonstrated experience producing engineering calculations, technical reports, specifications, and design documents.
• Credentialing to include the Professional Engineer (PE) license, Certified Process Safety Professional (CCPSC), Six Sigma Green Belt or Black Belt, Project Management Professional (PMP), or ISA Certified Automation Professional (CAP).
• Experience working within multidisciplinary engineering teams.

Skills/Abilities:

• Experience with EPC, design-build, or federal government projects.
• Experience with process automation and controls integration.
• Experience supporting construction, commissioning, and startup.
• Experience performing process safety analyses and risk assessments.
• Proficiency with Microsoft Office Suite, Excel-based engineering calculations, AutoCAD or AutoCAD Plant 3D, Bluebeam Revu, and other advanced modeling, simulation, and analytical software platforms.
• Experience leading small engineering task teams or discipline-specific work packages.
• Excellent work ethic and attitude.
• Excellent communication skills, organizational expertise, and the ability to plan, balance, and prioritize work.
• Ability to work within a team in field, hybrid, and office settings.
• Ability to lead a team and collaborate with multiple stakeholders.
• Ability to conduct site visits and field investigations, access industrial, manufacturing, and construction environments, occasionally lift up to 25 pounds and wear required PPE during field assignments.

Type: Full-Time

Travel: Yes, 10%

Compensation:

The expected base salary range for this role is $95,000-$115,000 per year. Actual compensation will be determined based on a number of factors including skills, experience, qualifications, and location.

This role is also eligible forperformance-based bonuses and a comprehensiveU.S. basedbenefits package, including:

• Medical, dental, and vision insurance
• 401(k) with company match
• Paid time off and company holidays
• Wellness programs and employee assistance resources

For more information, visit our full benefits overview here .

About Us:

Founded in 1975, Salas O’Brien is an employee-owned engineering and professional services firm focused on achieving impact for our clients, our team, and the world. We know that tomorrow’s requirements are today’s opportunities, and we are here to design lasting solutions for pressing challenges.

We work across a variety of industries providing integrated engineering and consulting services. Our specialized experience includes design for data centers, healthcare, science and technology, high-rise buildings, clean energy, education, and other building types as well as structural and building sciences, infrastructure asset management, advanced robotics, and more.

Our technical expertise is paired with an exceptional team of business development, human resources, finance and accounting, information technology, and marketing professionals, all of whom play a key role in bringing our commitments to life every day.

Salas O’Brien provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, colour, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state/provincial, or local laws. Salas O’Brien will accommodate the disability-related needs of applicants as required by law.

Qualifications

Education

Required

Bachelors or better in Chemical Engineering or related field.

Experience

Preferred

5-10 years:

5-10 years:

5-10 years of progressively responsible process engineering experience.

Licenses & Certifications

Preferred

Professional Engineer

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
This employer is required to notify all applicants of their rights pursuant to federal employment laws.For further information, please review the Know Your Rights notice from the Department of Labor.