Federal Process Engineer

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.

- 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.

- 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.

- 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 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.

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 for performance-based bonuses and a comprehensive U.S. based benefits package, including:

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.

Third-Party Agency Notice Salas O'Brien does not accept unsolicited resumes from external recruiters or agencies. We only work with approved partners engaged directly by our Talent Acquisition team for specific searches. Unsolicited submissions will not be eligible for placement fees.

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.