Senior Process Engineer
About the job
- A Bachelor's degree in Chemical Engineering or Mechanical Engineering.
- At least 15 years of experience working as a Process or Mechanical Engineer in industries such as oil refining, gas processing, power, or chemical industries.
- At least 7 years of experience working in power, refining or gas processing, petrochemical, or similar process safety management-regulated industries.
- At least 5 years of experience working in an engineering firm as a Process or Mechanical Engineer.
- Comprehensive understanding of processes typically seen in power and process plants.
- Experience applying standard engineering techniques, procedures, and design criteria to produce properly designed systems with accurate documentation and designs compliant with safety and environmental regulations.
- Experience developing process flow diagrams, piping and instrumentation diagrams, and equipment datasheets.
- Proficiency in heat and mass balance development, equipment and instrumentation process specification, and hydraulic analysis.
- Knowledge of performance guarantees, including emissions compliance.
- Experience specifying fixed and rotating equipment, including steam turbine generators, combustion turbine generators, and heat recovery steam generators.
- Strong knowledge of ASME and API 520/521, with proficiency designing relief devices and associated collection headers.
- Experience with process modeling software.
- Ability to travel less than 25% of the time, including client-site visits and walkdowns in industrial environments.
- Full compliance with site safety requirements and Zachry and client safety policies.
- Ability to meet schedule commitments and plan required resources.
- Ability to learn new technologies and apply them to current projects.
- Ability to maintain active status in a drug and/or alcohol testing consortium.
- Develop process flow diagrams, piping and instrumentation diagrams, and process/mechanical equipment datasheets.
- Develop heat and mass balances.
- Size and rate equipment such as pumps, horizontal and vertical vessels, heat exchangers, and air coolers.
- Perform hydraulic analyses and calculations for piping systems, including single-phase, two-phase, slurry, water-hammer, slug-flow, and distribution-network systems, using spreadsheet and rigorous software evaluations.
- Translate project design-basis requirements, client specifications, and contract documents into defined process tasks.
- Support the Zachry quality program by performing quality checks and verifying documentation of input data.
- Engineer and design the process engineering scope of assigned projects by independently evaluating, selecting, and applying standard engineering techniques, procedures, and criteria.
- Support projects as an individual contributor and, as needed, supervise, coordinate, and review the work of a small team of engineers to accomplish project or department objectives.
- Participate in client process hazard analysis reviews, including risk reviews, HAZID, and HAZOP/LOPA.
- Design relief systems, including contingency analysis, relief-valve sizing, flare-header design, and flare-header analysis.
- Present technical information to peers and clients for review and comment.
- Analyze problems and take appropriate action to ensure continuous and reliable operation of equipment and systems.
- Evaluate equipment and processes for compliance with safety and environmental regulations.
- Coordinate with the offshore High Value Engineering Center for engineering execution.
- Perform other assigned duties.
- A strong background developing heat and mass balances for combined-cycle projects.
- Licensed Professional Engineer.
- Experience using Thermoflow software tools to develop heat and mass balances and total installed cost estimates.
- Experience using Aspen HYSYS, AFT Fathom, Arrow, Impulse, Korf, HTRI, Flarenet, and iPRSM.
- Knowledge of or experience in the engineering, procurement, and construction power business.
- Experience designing outside battery limit and utility scopes supporting licensor packages and converting process design packages.
- Exposure to environmental permitting and citing studies.
- Active membership in professional organizations or committees.
About the company
Zachry Group provides turnkey engineering, construction, maintenance, turnaround and fabrication services for the energy, chemicals, power, manufacturing and industrial sectors in North America. It covers the full project lifecycle by helping customers plan, build and renew critical facilities, often as a single‑point provider responsible for the entire scope. The company executes projects through engineering, procurement, fabrication and on-site construction with a strong emphasis on safety and reliable delivery. What sets Zachry Group apart is its long history (since 1924), a purpose‑driven culture and a consistent focus on safety, quality and meeting customers’ immediate and long-term goals across diverse sectors. Its goal is to help clients achieve their objectives by delivering the best possible outcomes while maintaining high safety standards.
Company Size
5,001-10,000
Company Stage
N/A
Total Funding
N/A
Headquarters
San Antonio, Texas
Founded
1924
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Simplify's Take
What believers are saying
- NiSource awarded Zachry a 2025 EPC contract for a 2,600-megawatt Indiana project.
- Zachry Maintenance Services won 10-year Cheniere renewal on March 30, 2026.
- Chevron Phillips extended Zachry Maintenance Services five years on February 2, 2026.
What critics are saying
- Zachry's May 2024 Golden Pass bankruptcy exposed brutal project overruns and liquidity strain.
- July 30, 2026 Sabine Pass worker death triggered wrongful-death litigation against Zachry and Cheniere.
- Texas operations still carry labor and safety overhangs after 4,000-plus layoffs and WARN scrutiny.
What makes Zachry Group unique
- Zachry's 100-plus gas plants and 60,000-megawatt pedigree wins utility EPC work.
- Zachry's 2026 nuclear push, including Terrestrial Energy and new nuclear leaders, broadens optionality.
- Quanta joint venture on NiSource pairs Zachry engineering depth with stronger field execution.
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Benefits
Hybrid Work Options
Company News
Zachry Group awarded Engineering, Procurement, and Construction (EPC) contract for NiSource's Combined Cycle Generation Project. SAN ANTONIO-(BUSINESS WIRE)-Zachry Group (Zachry) has been awarded the Engineering, Procurement, and Construction (EPC) contract for NiSource Inc.'s Combined Cycle Generation Project, a major infrastructure project located near Wheatfield, Indiana. The facility will support NiSource's delivery of electricity to a third-party customer and includes two nominal 1,300-megawatt gas-fired combined cycle units in a 2 x 2 x 1 configuration. A subsidiary of NiSource Inc. will own and operate the facility. The EPC contract will be executed by a joint venture between Zachry Group and Quanta Services, Inc. (Quanta). Zachry will lead engineering, procurement, project management, construction planning, and commissioning, drawing on its five decades of experience designing and building over 100 gas-fired facilities totaling more than 60,000 megawatts. Quanta will contribute field-level leadership and craft workforce management through its operating companies. This collaborative approach is designed to enhance execution certainty, optimize labor resources, and deliver cost-effective, high-quality infrastructure. "We are honored to partner with NiSource Inc. on this landmark project that reflects our shared commitment to delivering reliable, efficient, and sustainable energy solutions," said John B. Zachry, Chairman and CEO of Zachry Group. "Working alongside Quanta, we're combining our complementary strengths to execute a project of this scale with precision and innovation. Together, we're proud to support the region's energy future." "NiSource is committed to advancing transformative growth while ensuring that customer affordability remains at the heart of our strategy," said Lloyd Yates, President and Chief Executive Officer of NiSource. "Through this collaboration with Zachry and Quanta, we are expanding generation and grid infrastructure in a way that supports economic development and innovation while protecting customers from the costs of infrastructure investment. We are excited to partner with Zachry and Quanta to meet the evolving energy needs of our customers and communities." "We're proud to collaborate with Zachry Group, a company that shares Quanta's commitment to safety, performance, and delivering results that matter," said Duke Austin, Quanta's President and Chief Executive Officer. "We have respected Zachry's capabilities for decades, and together, we look forward to delivering this critical infrastructure project for NiSource." About Zachry Group Zachry Group is North America's pacesetter in turnkey engineering, construction, maintenance, turnaround and fabrication services to the energy, chemicals, power, manufacturing and industrial sectors. We work with customers to plan, build, and renew their most critical facilities, so they can achieve their immediate and long-term goals, all at the highest safety standards. Since 1924, we have been a purpose-driven organization, united by a shared set of values and the desire to deliver the very best outcome for our customers. Visit www.zachrygroup.com for more information.
Shortly after the company pulled away from the natural gas project, the Zachry Holdings subsidiary (Zachry Industrial Inc.) laid off more than 4,000 workers.
BEAUMONT, Texas - Zachry Holdings has once again found itself facing scrutiny, after laying off 126 more people between Beaumont, Orange, Sabine Pass, and Baytown.
As the lead contractor in charge of staffing construction activities, Zachry's financial issues and ongoing bankruptcy proceedings have prevented the remaining contractors from resuming large-scale construction.
Zachry Holdings faces lawsuit, accusation of violating federal law in mass layoffs at Golden Pass LNG.