Senior Principal Process Engineer

Company: Worley

Primary Location

USA-WV-Charleston

Job

Process

Schedule

Full-time

Employment Type: Employee

Management Level: Individual Contributor

Job Posting

Sep 10, 2026

Unposting Date

Ongoing

Reporting Manager Title: Department Manager Process Engineering

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 a highly experienced Senior Principal Process Engineer to provide strategic technical leadership and process engineering team oversight for one large or several smaller specialty chemicals and chemicals projects. In this role, you will direct project execution activities and process engineering deliverable development while serving as a subject matter expert and technical authority across multiple projects and engineering teams. Accountable for the safe, sustainable, quality, cost, and schedule delivery of process engineering work, you will provide technical support, mentorship, quality oversight, and professional development for junior and mid-level engineers while ensuring successful project outcomes for Worley and its customers.

Key Accountabilities

Business Development Support

• Develop process engineering scopes of work, proposals, and professional services estimates for assigned projects.
• Support proposals by developing process engineering execution strategies, estimating costs, writing proposal content, and presenting to customers.
• Maintain an up-to-date professional profile and build positive working relationships with customers, suppliers, and contractors.
• Help strengthen Worley’s reputation as a trusted chemicals project partner.

Business Operations

• Communicate project resource plans, loading requirements, and skill needs to the Process Engineering Manager.
• Seek and obtain resources with the assistance of the Process Engineering Manager.
• Ensure project work is adequately covered during vacation periods and unplanned absences.
• Provide technical oversight, assign tasks, monitor progress, and mentor junior and mid-level engineers.
• Contribute to team knowledge sharing, training, mentoring, and professional development activities.
• Assist in employee performance review processes.
• Facilitate continuity of work when personnel transition from the team.
• Encourage compliance with Worley processes, standards, and requirements.
• Participate in office, process engineering team meetings, and team-building activities.
• Work to resolve inter-discipline, vendor, customer, and project issues.
• Ensure all process engineering activities meet health, safety, environmental, and security requirements.

Technical Competency

• Deliver process engineering services that meet Worley, customer, statutory, and regulatory requirements on time and within budget.
• Ensure adherence to generally accepted engineering principles, regulatory requirements, customer specifications, and industry standards.
• Apply knowledge of chemical reaction engineering, thermodynamics, separations, and material balances to develop safe and efficient process solutions.
• Incorporate environmental, health, and safety (EHS) considerations into designs, including OSHA, EPA, international regulations, and applicable regulatory requirements.
• Maintain a sound knowledge of local and international standards and statutory requirements.
• Ensure proper checking, peer reviews, and incorporation of comments and findings.
• Utilize local and global standards to support technical excellence.
• Support standardization of specifications, calculations, process deliverables, and engineering documentation.
• Keep current with developments in chemical process technologies, technical innovations, and industry best practices.

Project Execution

• Participate in project execution strategy and planning for chemicals projects, including revamps, expansions, debottlenecking, and grassroots facilities.
• Own process engineering scope, cost, schedule, and quality requirements.
• Effectively communicate project budget, schedule, and progress updates to stakeholders and the Process Engineering Manager.
• Initiate, manage, and supervise process engineering project requirements as required.
• Ensure project scope is clearly defined and changes comply with project change management processes.
• Own management of change for the discipline and maintain Management of Change (MoC) logs.
• Obtain client approvals for design modifications and maintain documentation of decisions and actions.
• Coordinate with other disciplines to ensure project success.
• Participate in relevant meetings, prepare progress reports, and follow required checking procedures.
• Participate in project design reviews and provide technical feedback.
• Respond promptly to interdisciplinary inquiries and review requests.
• Identify issues and problems, develop solutions, and seek assistance when required.
• Proactively resolve discrepancies between Worley and customer requirements.
• Support process optimization, yield improvement, and scale-up activities for chemical manufacturing processes.
• Take corrective actions regarding staffing requirements, scope changes, schedule impacts, or other issues affecting project completion.

Project Deliverables

Own, develop, check, approve, and provide technical authority for process engineering deliverables including, but not limited to:

Process Design Deliverables

• Process Flow Diagrams (PFDs)
• Heat and Material Balances (HMBs)
• Piping and Instrumentation Diagrams (P&IDs)
• Process Basis of Design documents
• Process engineering studies
• Process safety studies
• Technical reports

Process Simulation and Analysis

• Process models using Aspen Plus®, Aspen HYSYS®, Honeywell UniSim®, OLI Flowsheet®, Aveva Process Simulation™, and other applicable software.
• Line sizing, velocity, and pressure drop calculations.
• Hydraulic system evaluations and flow modeling.

Equipment Design and Specification

• Equipment sizing calculations and specifications for:
  • Reactors
  • Distillation systems
  • Separation systems
  • Utilities systems
  • Bulk separation vessels
  • Heat exchangers
  • Pumps
  • Compressors
  • Control valves
  • Pressure Safety Valves (PSVs)

Relief Systems and Process Safety

• Pressure Safety Relief System (PRS) overpressure analysis and sizing.
• Pressure Safety Valve (PSV) overpressure analysis and sizing.
• Relief system and flare evaluation and analysis.
• OSHA documentation and relief system evaluations in accordance with applicable industry standards.

Technical Reviews

• Review and comment on interdisciplinary deliverables including:
  • Piping layouts
  • Isometrics
  • 3D models
  • Mechanical equipment specifications
  • Related engineering deliverables
• Ensure technical issues are clearly defined, alternative solutions are evaluated, recommendations are documented, and customer approval is obtained where required.
• Review and authorize process engineering work completed by direct reports.

Procurement Support

• Ensure process engineering requirements are incorporated into equipment and material specifications, data sheets, testing requirements, and material requisitions.
• Support bid clarifications, bid evaluations, vendor document reviews, and approval activities.
• Review and authorize work completed by direct reports.

Site Support

• Participate in constructability, operability, and maintainability reviews.
• Provide assistance and technical advice during procurement, construction, commissioning, start-up, troubleshooting, operations, and maintenance activities.
• Support commissioning and start-up of chemical process units.
• Participate as a technical expert in PHA, HAZOP, and LOPA studies.
• Work with site personnel to resolve technical issues.
• May provide or lead on-site support during construction, commissioning, and project turnover activities.

What You Will Bring

Technical and Industry Experience

• Demonstrated ability to lead process engineering activities for multiple simultaneous chemicals industry projects.
• Strong experience working on multi-disciplinary projects and teams.
• Advanced technical and practical process engineering skills with a proven record of delivering accurate, high-quality, and timely work.
• Strong understanding of process engineering fundamentals and working knowledge of other engineering disciplines.
• Strong knowledge of chemical process safety, EHS requirements, applicable regulations, codes, standards, and industry practices.
• Experience supporting specialty chemical, chemical, petrochemical, or related industries.
• Experience with revamps, expansions, debottlenecking, and grassroots chemical facilities.
• Experience in project leadership and supervision of engineering teams.
• Skilled in estimating project costs and developing proposal content.

Process Engineering Software

Process Simulation

• Aspen Plus®
• Aspen HYSYS®
• Honeywell UniSim®
• OLI Flowsheet®
• 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
• Hydraulic modeling software

Other Tools

• Internal and external calculation tools
• Microsoft Office Suite

Qualifications, Accreditation, Training

Required

• Bachelor’s or Master’s degree from an ABET-accredited university in Chemical Engineering or a related engineering field.
• Typically 12+ years of relevant process engineering experience, including chemicals or specialty chemicals project execution, and 3+ years of demonstrated project leadership.

Preferred

• Professional Engineer (PE) license.
• Experience in specialty chemicals, petrochemicals, or related chemical industries.
• Experience with revamps, expansions, and debottlenecking in operating chemical facilities.
• Training in risk management or quality.

HSE Capability

• Assume hands-on management and implementation of all relevant company HSE requirements.
• Drive safe and sustainable engineering outcomes throughout the asset lifecycle.
• Incorporate environmental, health, and safety considerations into process designs.
• Role model a commitment to personal well-being and continuous improvement in health, safety, and environmental performance.

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.