Senior Process Engineer

INEOS Olefins & Polymers USA

Interested in joining a winning team? A team whose employees are empowered to make a difference?

Job title: Senior Process Engineer - Capital Projects

Job Grade: H35

Location: League City, TX

Travel: Minimal; limited to local contractor offices, nearby fabrication shops, or plant sites as required

INEOS has grown to become a leading chemical company, with sales today of around $68 billion annually. INEOS is a global company with 26,000 employees on 180 sites in 30 countries.

The Olefins & Polymers USA (O&P USA) Business within INEOS includes the product lines Ethylene, Propylene, Butadiene, Polypropylene (PP) and Polyethylene (PE). Our 4 Manufacturing sites encompass Chocolate Bayou Works (Alvin, TX), Battleground Manufacturing Complex (LaPorte, TX), and Carson (Carson, CA), with a division office in League City, TX. Overall, O&P USA has approximately 1,300 employees, 1,400 contractors, and annual revenue of $6.5 billion.

Purpose of the Job

The Senior Process Engineer provides process design expertise, owner’s-team leadership, and technical stewardship at the project and asset level across the Olefins & Polymers asset base. The role leads development and assurance of process engineering deliverables for capital projects, reliability improvements, and operational enhancements from FEL1 through commissioning, ensuring designs are safe, operable, reliable, and aligned with business objectives.

The position acts as a project- and asset-level process engineering authority, guiding critical design decisions and ensuring disciplined engineering quality.

Accountabilities of the Job

Accountability 1: Process Engineering Expertise & Technical Stewardship

Most important activities

· Lead development of Heat & Material Balances using rigorous simulation and sound engineering fundamentals, covering normal, startup/shutdown, upset, turndown, and emergency scenarios, including utility and relief implications.

· Apply strong process design fundamentals to develop and review major equipment specifications, including reactors, columns, furnaces, heat exchangers, compressors, pumps, tanks, fired heaters, and utility systems.

· Produce and assure high-quality PFDs, P&IDs, line lists, hydraulic calculations, control narratives, safeguarding philosophies, and Cause & Effect matrices, ensuring internal consistency across all deliverables.

· Provide technical input to relief system design, SIS requirements, interlock schematics, and flare or disposal system basis, applying IEC 61511 and ISA84 principles.

· Embed process safety through participation in HAZOP, LOPA, SIL determination, and facility siting, and steward timely closeout of actions.

· Maintain process integrity through disciplined Management of Change.

Accountability 2: Capital Project Development (FEL1–FEL3)

Most important activities

· Lead frontend process engineering using sound engineering judgment and technical trade-off evaluation, comparing options for lifecycle value including capital cost, operating cost, energy efficiency, operability, reliability, and risk.

FEL1 – Opportunity Evaluation

· Develop Options Maps and Scope of Facilities; define initial process philosophies and conceptual Heat & Material Balances.

· Identify early permitting constraints and support Class V estimate inputs and high-level schedule logic.

· Establish the Process Engineering Quality Management Plan for FEL2.

FEL2 – Selection

· Validate and update the BEDD and contribute to development of the Project Design Basis.

· Participate in Optioneering and Value Improvement Practices.

· Provide rigorous QA/QC of contractor process deliverables, challenging assumptions and ensuring alignment with the approved design basis.

· Support interdisciplinary reviews and development of Class III estimates.

FEL3 – Definition

· Approve key process deliverables and steward closure of open technical decisions and action items.

· Confirm readiness of process engineering packages for transition to Execute and EPC phases.

· Validate process assumptions used in Class II and Class III estimates.

Accountability 3: Detailed Engineering, Contractor Management & Quality Assurance

Most important activities

· Serve as Owner’s Process Lead for assigned projects during detailed design, ensuring alignment with the approved design basis and safeguarding requirements.

· Review contractor deliverables including PFDs, P&IDs, hydraulic calculations, equipment datasheets, relief designs, and control narratives.

· Critically review change notifications and distinguish legitimate scope changes from design evolution.

· Resolve cross-discipline issues with Mechanical, Electrical, Instrumentation & Controls, Civil/Structural, and Process Control.

· Drive early identification and closure of design gaps to reduce late changes and rework.

Accountability 4: Construction, Commissioning & Startup Support

Most important activities

· Provide process engineering support during construction, including response to field queries and review of deviations relative to design intent.

· Participate in PSSR, pre-commissioning, and commissioning readiness activities.

· Support startup activities including control loop tuning support, SIS validation support, troubleshooting, and performance testing.

· Review redlines and as-built documentation for accuracy and contribute to project close-out and lessons learned.

· Accountable for the technical quality and integrity of process engineering deliverables, not for long-term asset operating results.