Senior Process Engineer Jobs in EPC Projects – Apply for Oil, Gas, Refinery & Chemical Plant Roles (2025)
Senior Process Engineer – Engineering, Procurement & Construction (EPC) Projects
Position Title: Senior Process Engineer
Function: Process Engineering
Minimum Qualification: Bachelor of Engineering (BE)
Location: [Specify Location]
Industry: Fertilizers, Chemicals, Petrochemicals, Oil & Gas, Refinery, Specialty Chemicals, Utilities
Job Overview
We are looking for an experienced Senior Process Engineer to join our dynamic engineering team. The ideal candidate will bring a strong background in basic and detailed engineering for large-scale process plants such as fertilizers, chemicals, petrochemicals, oil & gas, and refinery facilities. This role is pivotal in ensuring engineering excellence and delivering projects within scope, time, and budget, while meeting all quality and compliance standards.
Key Responsibilities
1. Process Design and Engineering Execution
- Lead and manage basic and detailed process engineering for multiple full project life cycles in EPC/EPCM environments.
- Handle greenfield, brownfield, and revamp projects from concept to commissioning.
- Prepare and review essential process documents including:
- Process Flow Diagrams (PFDs)
- Piping & Instrumentation Diagrams (P&IDs)
- Process datasheets
- Heat and Material Balances (HMB)
- Hydraulic and network sizing studies
- Ensure timely and quality delivery of process engineering deliverables across FEED and detail engineering stages.
2. Technical Leadership and Project Oversight
- Provide oversight of process engineering throughout EPC phases—engineering, procurement, and construction.
- Lead technical teams in concept and feasibility study execution.
- Optimize existing facility operations in ongoing refinery, chemical, and petrochemical plants.
- Provide technical support during pre-bid activities and value engineering exercises.
3. Process Simulation and Engineering Tools
- Proficient in industry-standard simulation and engineering tools:
- Aspen HYSYS
- PRO II
- Flare Net
- HTRI
- Hydraulics and Network modeling software
- Perform equipment sizing and process calculations for:
- Heat exchangers
- Knock-out drums
- Desalters
- Sour water strippers
- Storage tanks
- Relief devices and control valves
4. Compliance and Safety
- Ensure compliance with local statutory requirements and international process safety standards.
- Conduct and participate in safety studies such as:
- HAZOP (Hazard and Operability Study)
- HAZID (Hazard Identification)
- SIL (Safety Integrity Level)
- Apply good engineering practices in accordance with ASTM, ASME, ANSI, API, OISD, EIL, NFPA, IBR, and SMPV standards.
5. Cross-Disciplinary Coordination
- Work collaboratively with cross-functional teams including:
- Project Management
- Civil & Structural
- Mechanical & Piping
- Instrumentation & Control
- Electrical Engineering
- Manage technical inputs and interface integration across all project phases.
6. Knowledge Management and Continuous Improvement
- Document key learnings from ongoing and completed projects in the Knowledge Management (KM) Portal.
- Conduct regular knowledge sharing sessions and promote organizational learning.
- Continuously improve process engineering tools, methodologies, and practices through real-time feedback and innovation.
Required Skills and Qualifications
- Educational Background: BE/BTech in Chemical, Mechanical, or related discipline.
- Experience: Minimum 10–15 years in process engineering with at least 4 full-cycle EPC/EPCM projects.
- Technical Competence:
- In-depth knowledge of process design for complex process plants.
- Hands-on experience in simulation, hydraulics, sizing, and plant optimization.
- Proficiency in process engineering software (AspenTech Suite, PRO II, etc.)
- Safety & Standards: Strong grasp of HSE standards, safety analysis techniques, and global engineering codes.
- Communication & Leadership: Excellent verbal and written communication skills with strong leadership qualities.
Why Join Us?
- Industry Exposure: Work on multi-billion-dollar projects in refinery, oil & gas, and chemical sectors.
- Innovation & Growth: Be part of a team that values process innovation and operational excellence.
- Collaborative Culture: Interface with top-tier professionals from engineering, procurement, and project management.
- Advanced Tools: Gain access to the latest software, modeling techniques, and continuous training.
- Impactful Work: Your contributions directly affect plant performance, energy efficiency, and safety improvements.
Project Types and Engineering Scope
- Greenfield Projects – Complete engineering for new units and process blocks.
- Brownfield Projects – Integration with existing infrastructure and systems.
- Revamp Projects – Upgradation and debottlenecking of existing process units.
- FEED (Front-End Engineering Design) – Concept development and preliminary engineering.
- Detail Engineering – Finalizing specifications, detailed layouts, and interface management.
Deliverables and Key Outcomes
- Process Design Documents (PFDs, P&IDs, Datasheets)
- Hydraulic and Energy Balance Reports
- Simulation Models and Reports
- Equipment Sizing and Specification Documents
- Safety Analysis Reports (HAZOP, SIL)
- Inter-discipline Review Documents and Clarification Logs
- Knowledge Sharing Presentations and KM Uploads
Ideal Candidate Profile
The ideal candidate is a process-driven, detail-oriented engineer who can think strategically and execute tactically. You thrive in high-pressure environments, consistently deliver quality work, and possess the ability to lead and collaborate effectively across teams.
You are passionate about process engineering, driven by continuous learning, and committed to upholding safety and engineering standards in everything you do.