Sr. Project/Process Engineer

SENIOR PROCESS / PROJECT ENGINEER

GMM Pfaudler Systems | Process Systems Technologies | Rochester, New York

Engineer custom process systems from concept through commissioning.

This is not a narrowly defined process-engineering or project-coordination role. You will develop the process, engineer the equipment and instrumentation, guide the physical system design, manage suppliers and fabrication, and help bring the completed system online at the customer site.

SUMMARY OF POSITION

GMM Pfaudler US Inc. is a leading supplier of highly engineered, critical equipment and process systems for energy, chemical, and industrial markets. The Process Systems Technologies (PST) group designs and fabricates complete modular process systems, including Reactor Systems, Wiped Film Evaporator (WFE) Systems, Distillation Systems, and other specialized process systems.

We are seeking an experienced chemical process engineer to join the PST Group as a Senior Process / Project Engineer. The position is based in our Rochester, NY office.

Every system we design is custom engineered for a client's specific process and production needs. Our work serves a broad range of industries, including specialty chemicals, pharmaceuticals, nutraceuticals, petrochemicals, polymers, and others. Projects may involve converting customer or GMM Pfaudler pilot-test data into a commercial-scale production system or evaluating and improving an existing process to increase capacity, product quality, and ease of operation.

The Senior Process / Project Engineer has broad technical and execution responsibility. The role combines process design, equipment and instrumentation engineering, piping-system definition, technical procurement, 3D-model and drawing coordination, modular-system fabrication oversight, documentation, factory acceptance testing, startup, and field commissioning.

You will work directly with customers, Application Engineers, CAD Designers, equipment engineers, operations personnel, vendors, contractors, and fabricators. The result is an opportunity to take genuine ownership of complex, custom-engineered systems and see your engineering decisions become operating process plants.

WHY THIS ROLE IS DIFFERENT

• Own engineering work across the complete project lifecycle, from Basis of Design through startup.
• Apply core chemical-engineering principles to real custom systems involving heat transfer, fluid flow, mass transfer, evaporation, reaction, vacuum, distillation, and related unit operations.
• Engineer the complete system, including equipment, instrumentation, piping, utilities, relief protection, and operating requirements.
• Work on varied projects across multiple process industries rather than repeatedly executing one standard product design.
• Collaborate directly with customers and guide designers, vendors, fabricators, and contractors in turning the process design into a buildable modular system.
• Monitor the equipment and modules being fabricated and help commission completed systems at customer facilities.
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ESSENTIAL DUTIES AND RESPONSIBILITIES

Depending on the size and structure of the assignment, the Senior Process / Project Engineer may lead the technical execution of a project or support the Project Manager and other senior engineering personnel. In either case, the engineer is expected to take active ownership of assigned work, coordinate across disciplines, identify and resolve issues, and help drive the project to successful completion. Duties may be modified, and other duties may be assigned as necessary.

Process Engineering Activities

• Work with customer representatives and PST Application Engineers to define applicable standards, regulations, physical constraints, process requirements, performance expectations, and other information required to establish the Project Basis of Design.
• Develop Process Flow Diagrams (PFDs). Complete mass and energy balance calculations and required utility calculations, including temperatures, pressures, and flow rates. Tabulate the results in a Mass and Energy Balance (MEB) and guide the CAD Designer in preparing the associated drawings.
• Develop Piping and Instrumentation Diagrams (P&IDs) for the process and guide the CAD Designer in preparing and revising the drawings.
• Define and size process equipment such as heat exchangers, evaporators, tanks, reactors, pumps, vacuum equipment, and other system components.
• Define the instrumentation and final control elements needed to measure and control temperature, pressure, flow, level, and other process variables. Devices may include sensors, transmitters, gauges, switches, control valves, and related components.
• Define and size piping-system components, including pipe, valves, fittings, strainers, expansion bellows, flexible hoses, and other specialty items.
• Develop pressure-relief scenario assumptions and size pressure-relief devices, including pressure-relief valves and rupture disks.
• Participate in customer Process Hazard Analyses, PHAs, or HAZOPs through online meetings or travel to customer sites, and provide the engineering support needed to evaluate and resolve action items.
• Travel to customer sites after system installation to provide startup and commissioning engineering support.
• Provide post-startup technical support to customers as needed.

Project Engineering Activities

• Participate in and contribute to internal and customer project meetings, design reviews, 3D-model reviews, hazard reviews, schedule discussions, and technical issue-resolution meetings.
• Work with the GMM Pfaudler Equipment Engineering Group and Operations to ensure that GMM Pfaudler equipment, including reactors and WFEs, is correctly specified, designed, fabricated, documented, and completed in accordance with project requirements and schedule needs.
• Specify and procure the equipment, instrumentation, valves, and piping items required for the process. Responsibilities include developing specification sheets and bid packages, obtaining competitive quotations, completing technical evaluations, resolving vendor exceptions and clarifications, recommending suppliers, and supporting procurement.
• Guide the CAD Designer in developing the complete 3D model to achieve a technically correct, constructible, ergonomic, operable, and maintainable system layout.
• Guide the preparation of equipment-layout drawings, structural-steel drawings, orthographic drawings, piping-isometric drawings, spool drawings, tie-point drawings, and bills of materials. Complete detailed technical checks of the model and all project drawings.
• Prepare specification packages for fabrication of the modular systems, obtain and evaluate fabrication bids, and participate in selecting the fabricator.
• Coordinate technical information and interfaces among customers, internal engineering groups, equipment suppliers, instrument vendors, fabricators, and contractors.
• Prepare Factory Acceptance Test (FAT) documents and, when required, Site Acceptance Test (SAT) documents.
• Prepare project operating manuals that include the Basis of Design, installation instructions, process description, description of operation, equipment index, instrument index, line list, valve list, tie-point list, lubrication schedule, spare-parts list, and manufacturers documentation for purchased components.

Construction Management and Acceptance Activities

• Travel to equipment-supplier and module-fabricator facilities to monitor progress and inspect equipment and modular-system construction for compliance with approved specifications, drawings, documentation, and project requirements.
• Review supplier and fabricator documentation for accuracy, completeness, and compliance with technical and commercial requirements.
• Provide timely engineering direction to resolve fabrication questions, nonconformances, interferences, substitutions, and other construction issues.
• Conduct or support the FAT, document punch-list items, and verify that deviations and deficiencies are corrected before shipment or project closeout.

Application Engineering and Estimating Support

From time to time, assist a PST Application Engineer with customer inquiries and proposal development. Activities may include process and equipment sizing, instrument selection and costing, preliminary system layouts, modular-fabrication concepts, and cost estimating.

WHAT MAKES A SUCCESSFUL CANDIDATE

• Enjoys combining process engineering with hands-on project execution and practical design decisions.
• Takes ownership of technical details and follows commitments through procurement, fabrication, testing, and commissioning.
• Can move comfortably between calculations, specifications, P&IDs, 3D-model reviews, vendor discussions, shop inspections, and customer meetings.
• Balances technical rigor with constructability, operability, maintainability, schedule, cost, and customer needs.
• Works independently as a self-starter while remaining collaborative, responsive, and customer focused.
• Communicates complex technical information clearly in both written and verbal form.
• Approaches project problems with sound judgment, persistence, and a practical focus on resolution.

SUPERVISORY RESPONSIBILITIES

This position has no direct personnel-supervision responsibilities. The engineer will, however, provide technical direction to CAD Designers and monitor, review, and approve fabrication or construction work performed by vendors and contractors within the assigned scope.

TRAVEL

Most customer and project communications are conducted by email, telephone, and online meetings. Occasional travel to customer, vendor, equipment-supplier, and fabricator sites is required. Anticipated travel is light, generally less than 5%.

QUALIFICATIONS

Required Relevant Experience

• A minimum of ten (10) years of experience in chemical-process-system design, including application of heat transfer, fluid flow, mass transfer, and related chemical-engineering principles.
• Demonstrated experience defining or designing process equipment, instrumentation and control devices, and piping systems.
• Ability to read, interpret, and develop technical documents and drawings, including engineering specifications, PFDs, and P&IDs.
• Strong verbal and written communication skills for work with customers, internal project teams, vendors, fabricators, contractors, and other stakeholders.
• Demonstrated ability to work independently as a self-starter while contributing effectively as a team member and maintaining a strong customer-service focus.
• Project-engineering and project-management experience is preferred and considered a plus.

Computer Skills

Required:

• Microsoft Word, Excel, and PowerPoint for specifications, calculations, tabulations, presentations, correspondence, and general project work.

Preferred and considered a plus:

• Aspen Plus or similar software for process simulation.
• Aspen Exchanger Design or similar software for heat-exchanger sizing.
• Microsoft Project or similar software for project scheduling.

EDUCATION

A Bachelor of Science degree in Chemical Engineering is required.

LANGUAGE AND COMMUNICATION SKILLS

• Speak and write English proficiently.
• Communicate effectively in technical discussions with customers to understand their needs, clarify requirements, and explain GMM Pfaudler designs and recommendations.
• Communicate effectively with vendors, fabricators, and contractors to define requirements, resolve technical questions, and coordinate execution.
• Prepare technically sound specifications, instructions, calculations, reports, operating documentation, and professional project correspondence.

MATHEMATICAL AND TECHNICAL SKILLS

Ability to complete the process-design calculations required for assigned systems, including mass and volumetric flow rates, mass and energy balances, heat transfer, mass transfer, fluid flow, pressure drop, pressure and temperature relationships, equipment sizing, and unit conversions.

REASONING ABILITY

Ability to interpret written, verbal, and diagrammatic information; recognize missing or conflicting requirements; identify technical and project risks; apply sound engineering judgment; and troubleshoot typical project, fabrication, installation, and startup problems to achieve practical resolutions.

CERTIFICATES, LICENSES, AND REGISTRATIONS

None required.

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally required to stand, walk, sit, use hands to grasp, handle, or feel, reach with hands and arms, climb or balance, stoop, kneel, or crouch, and communicate verbally. Specific vision abilities include close vision, color vision, peripheral vision, depth perception, and the ability to adjust focus.

WORK ENVIRONMENT

The position is primarily performed in a typical office environment. The employee will also be required to enter GMM Pfaudler or vendor workshop environments to monitor job progress, inspect equipment and system components, support testing, and accompany customers during inspections. The employee may visit customer plant sites to review existing or proposed installations and to commission new process systems. Customer facilities may include operating chemical and pharmaceutical plants where all site-specific safety rules and requirements must be followed.

EMPLOYER STATEMENT

All requirements are subject to possible modification to reasonably accommodate individuals with disabilities. This job posting in no way states or implies that these are the only duties to be performed for this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor. This document does not create an employment contract, implied or otherwise.

GMM Pfaudler US Inc provides equal employment opportunities to all employees and applicants for employment. We prohibit discrimination based on race, color, religion, age, sex, national origin, disability, genetic information, protected veteran status, sexual orientation or any other characteristic protected by federal, state, or local law.