Senior Process Engineer

Worley; Charleston (WV); On-site; USD 120,000 - 180,000; Full time

Job summary

Worley is seeking an experienced Senior Process Engineer to lead chemical engineering projects, mentor engineers, and ensure safe, cost-effective delivery across the project lifecycle.

You will provide technical leadership on process design, safety studies, and regulatory compliance while supporting project execution from concept through start-up in a dynamic, global engineering environment.

Qualifications

• Experience leading chemical process engineering projects with multiple concurrent workstreams.
• Strong knowledge of chemical process safety, EHS regulations, and applicable standards.
• Proficiency with process simulation and equipment sizing tools listed above.

Responsibilities

• Lead process engineering deliverables for chemicals projects, coordinating with PMs and stakeholders.
• Define scope, develop cost estimates, proposals, and maintain budgets/schedules.
• Own and check key deliverables: PFDs, HMBs, P&IDs, process models, and safety studies.
• Support commissioning, start-up, and troubleshooting activities.

Skills

Process engineering leadership

Chemical industry experience

Regulatory compliance

Mentoring and coaching

Project management

Education

Bachelor’s or Master’s degree in Chemical Engineering

Tools

Aspen Plus

HYSYS

OLI Flowsheet

UniSim

Aveva Process Simulation

Aspen Flare System Analyzer

UniSim Flare

HTRI Xchanger Suite

UniSim Heat Exchangers

AFT Suite

Job description

About Us

Worley is a global company of energy, chemicals and resources experts headquartered in Australia. We partner with our customers to deliver projects and create value across the life of their assets. We specialize in consulting, engineering, procurement and construction across the project lifecycle, with services extending through to operations and decommissioning. Leveraging extensive experience and AI-enabled delivery, we support customers in navigating complexity as they meet today's needs and transition to more sustainable solutions.

About Us

Worley is a global company of energy, chemicals and resources experts headquartered in Australia. We partner with our customers to deliver projects and create value across the life of their assets. We specialize in consulting, engineering, procurement and construction across the project lifecycle, with services extending through to operations and decommissioning. Leveraging extensive experience and AI-enabled delivery, we support customers in navigating complexity as they meet today's needs and transition to more sustainable solutions.

Purpose

We're looking for an experienced Senior Process Engineer to support our Chemicals business. 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.

Key Accountabilities

Project & Team Leadership

• Serve as the senior process engineer on chemicals projects, reporting to the Process Engineering Manager.
• Communicate project resource needs and coordinate with the Process Engineering Manager.
• Provide updates on budget, schedule, and progress to stakeholders.
• Assign tasks, provide oversight, and mentor junior and mid-level engineers.
• Support project execution strategies tailored to the chemicals industry, including revamps, expansions, debottlenecking, and grassroots projects.

Process Engineering Delivery

• Deliver engineering services that meet Worley, client, and regulatory requirements—on time and within budget.
• Define scope of work, prepare proposals, and develop cost estimates.
• 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

Chemicals Industry Focus

• Apply knowledge of chemical reaction engineering, thermodynamics, separations, and material balances to design safe and efficient systems.
• Incorporate environmental, health, and safety (EHS) considerations into designs, with an emphasis on OSHA, EPA, and international regulations.
• Support process optimization, yield improvement, and scale-up for chemical manufacturing.
• Participate in PHA, HAZOP, and LOPA for chemicals projects as a technical expert.
• Provide technical support during commissioning, start-up, and troubleshooting of chemical process units.

Collaboration & Support

• Review and comment on interdisciplinary deliverables (piping layouts, isometrics, 3D models, mechanical equipment specifications, etc.).
• Support procurement, construction, and commissioning activities.
• Maintain Management of Change (MoC) logs and secure client approvals.
• Proactively resolve issues and discrepancies with clients.

Continuous Improvement

• Stay current with developments in chemical process technologies and industry best practices.
• Contribute to team knowledge sharing, training, and mentoring.
• Help strengthen Worley’s reputation as a trusted chemicals project partner.

What You Will Bring

Technical & Industry Experience

• Proven ability to lead process engineering for multiple chemical industry projects simultaneously.
• Strong background in multi-disciplinary projects and teamwork.
• Advanced technical and practical skills with a track record of delivering accurate, high-quality work in chemicals.
• Knowledge of chemical process safety, EHS regulations, and applicable local/international standards.
• Proficiency in process engineering software, including:
• Simulation: Aspen Plus®, HYSYS®, OLI Flowsheet, UniSim, Aveva Process Simulation™
• Flare Header Evaluations: Aspen Flare System Analyzer™, UniSim Flare
• Heat Exchanger Sizing: HTRI Xchanger Suite, UniSim Heat Exchangers
• Flow Modeling: AFT Suite (Fathom, Arrow, Impulse), Korf, PipeFlo
• Other: Internal/external calculation tools and MS Office Suite

Education & Qualifications

• Required: Bachelor’s or Master’s degree in Chemical Engineering (ABET-accredited).
• Preferred:
• Professional Engineer (PE) license.
• Experience in specialty chemicals, petrochemicals, or related chemical industries.
• Prior experience with revamps, expansions, and debottlenecking in operating chemical plants.

Moving forward together

We want our people to be energized and empowered to drive sustainable impact. So, our focus is on a values-inspired culture that unlocks brilliance through belonging, connection and innovation. We're building a diverse, inclusive and respectful workplace. Creating a space where everyone feels they belong, can be themselves, and are heard.

And we're not just talking about it; we're doing it. We're reskilling our people, leveraging transferable skills, and supporting the transition of our workforce to become experts in today's low carbon energy infrastructure and technology. Whatever your ambition, there's a path for you here.

And there's no barrier to your potential career success. Join us to broaden your horizons, explore diverse opportunities, and be part of delivering sustainable change.