Senior Process Engineer

Worley • Charleston, WV

3d

About The Position

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.

Requirements

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

Nice To Haves

• Professional Engineer (PE) license.

Responsibilities

• 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.
• 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.
• 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.
• 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.
• 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.

Benefits

• 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.
• 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.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior