Staff Process Engineer

Commonwealth Fusion Systems•Devens, MA

1d•$152,000 - $230,000•Onsite

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Staff Process Engineer with strong chemical engineering fundamentals and extensive experience scaling up, commissioning, and operating systems in large industrial facilities. The engineer will own complex process engineering scopes and guide systems from early concepts through front-end loading (FEL), detailed engineering, construction, commissioning, and operation. The work involves translating fundamental requirements into practical, commercially viable industrial systems, including projects with loosely defined outcomes. The role spans technologies and systems associated with fusion power plants, including nitrogen and helium cryogenics, steam power generation, molten salts (FLiBe), deuterium-tritium fueling, gas processing, vacuum systems, and utilities. The engineer will establish process design bases, develop balances and models, size and specify equipment, own P&IDs, lead process safety work, support startup, and troubleshoot operating systems. The position also provides technical leadership, manages project risks, and mentors less-experienced engineers. This full-time role offers a salary range of $152,000–$230,000 per year, plus equity and benefits. The actual salary depends on level, location, qualifications, and experience. The role requires occasional travel or work at night, on weekends, or on call, and hands-on work in industrial, construction, commissioning, and operating environments. It also involves physical activity and potential exposure to industrial hazards. The role requires compliance with U.S. export control laws.

Requirements

Bachelor’s degree in Chemical Engineering or a closely related discipline.
10 or more years of relevant industrial process engineering experience, potentially fewer with a Ph.D., or equivalent demonstrated depth of experience.
Demonstrated deep domain expertise or broad expertise across domains, with the ability to independently own complex, semi-ambiguous work and seek support when needed.
Strong command of chemical engineering fundamentals and a track record of taking systems through structured FEL or phase-gated development.
Experience scaling loosely defined process requirements into commercial-scale equipment and facilities.
Deep expertise developing process engineering deliverables, including design bases, PFDs, P&IDs, heat and material balances, and sizing or selecting industrial process equipment.
Hands-on experience commissioning, operating, and troubleshooting physical equipment alongside operators, using field observations to diagnose performance.
Proficiency with process simulation tools such as EcoSim, Aspen HYSYS/Plus, or AVEVA.
Extensive experience applying industry codes and standards, such as ASME B31.3, ASME BPVC Section VIII, and API 520/521, to establish process design boundaries, fluid service classifications, operating envelopes, and relief/depressurization cases.
Strong background in process safety, hazard identification and risk analysis such as HAZOP, and relief system design.
Experience integrating cross-functional engineering disciplines and working directly with vendors, EPC organizations, or construction contractors.
Ability to independently manage medium risks, drive solutions for larger project risks, and apply strong engineering judgment to produce practical, commercially viable designs.
Values aligned with CFS’s values of integrity, execution, impact, and self-critique.
Ability to lift up to 50 pounds occasionally.
Ability to stoop, climb, type, stand, and sit for extended periods.
Willingness to occasionally travel or work required nights, weekends, or on call.
Willingness and ability to work hands-on in industrial, construction, commissioning, and operating environments.
Dedication to safety and ability to work around potential hazards including heat, cold, noise, fumes, strong magnets, lead, high voltage, high current, pressure and vacuum systems, hazardous materials, and cryogenics.
Compliance with U.S. laws concerning export-controlled or protected technologies and information is required; any employment offer is contingent on this compliance.

Nice To Haves

Experience with large-scale cryogenic systems, particularly supercritical or liquid helium, and industrial high-vacuum systems.
Background in large-scale process facilities such as power generation, petrochemical, LNG, industrial gases, or nuclear.
Expertise in steam systems, molten salt systems, or industrial gas processing, including purification, separation, or fueling.
Experience with large-scale utilities such as cooling water, chilled water, compressed or instrument air, and nitrogen.
Track record of scaling first-of-a-kind technologies from pilot or demonstration scale to commercial operation.
Experience with dynamic process simulation and consequence analysis.
Professional Engineer licensure.

Responsibilities

Own the process engineering scope for complex systems with loosely defined outcomes, guiding them from early concept through operation with near-complete independence.
Translate engineering requirements into process design bases, operating envelopes, PFDs, heat, material and utility balances, P&IDs, and process datasheets.
Apply chemical engineering fundamentals to resolve technical challenges and define operating boundaries.
Develop steady-state and dynamic process models to inform process design, system architecture, and equipment selection.
Size, specify, and evaluate process equipment, working with suppliers, fabricators, and multidisciplinary teams to assess performance, safety, and cost tradeoffs.
Drive engineering through phase-gated design, progressively maturing systems from concept to engineering definition.
Lead process safety activities, including HAZOPs, design reviews, and relief/depressurization studies; develop control philosophies and interlocks with controls engineers.
Support field execution by preparing work and commissioning plans, test procedures, and startup strategies; participate in commissioning and performance testing.
Troubleshoot operating equipment using first-principles engineering and field data, and turn lessons learned into process improvements, tools, and department policies.
Provide technical leadership, manage medium-to-large project risks, drive solutions, and mentor less-experienced engineers.
Occasionally travel to suppliers, contractors, or operating facilities, and work required nights, weekends, or on call.
Work hands-on in industrial, construction, commissioning, and operating environments while following safety practices.