Process Engineer

About the role

NorthStar Energy Services is seeking an experienced Process Engineer to join our Professional Engineering Consulting team. This role supports energy and industrial projects across oil & gas processing, pipelines, petrochemical facilities, and related infrastructure. The Senior Process Engineer will lead process design development, ensure regulatory compliance, and coordinate with multidisciplinary teams to deliver high-quality engineering solutions from concept through detailed design.

Responsibilities

• Develop process design concepts, engineering criteria, and calculations for energy processing facilities and pipeline systems.
• Perform process engineering analyses including material and chemical balances, hydraulic calculations, compression analysis, overpressure protection, and maximum intended inventory.
• Generate and maintain process documentation such as PFDs, P&IDs, mass balance diagrams, logic diagrams, and cause & effect matrices.
• Lead and participate in process safety activities including HAZOPs, LOPA studies, and PSM documentation.
• Support the detailed design and specification of process systems and equipment including compressor stations, pump stations, storage facilities, metering systems, gas treating, dehydration, utility systems, and flare/relief systems.
• Career Development: Participate in professional development opportunities and contribute to the growth of the team.

Requirements

• Bachelor’s degree in Chemical or Petroleum Engineering or related discipline.
• Professional Engineer (P.E.) license required, preferably in Texas.
• 10+ years of total experience, 5 years of direct process engineering experience supporting oil & gas, pipeline, petrochemical, or industrial facilities.
• Proven experience developing detailed process designs for facilities such as compressor stations, pump stations, storage terminals, and utility systems.
• Strong working knowledge of applicable codes and standards including: Title 49 CFR Parts 190–199, 40 CFR 112, 40 CFR 264, ASME BPVC Section VIII, ASME B31.3 / B31.4 / B31.8, API 610, 674, 675, 676, 682, 520, 521, API 620, 650, and 12C.
• Experience with pressure relief systems, flare design, chemical injection, truck/rail loading systems, and fire suppression integration.
• Strong analytical, organizational, and problem-solving skills with exceptional attention to detail.
• Excellent written, verbal, and presentation communication skills.

Qualifications

• Strong leadership and teamwork skills.
• Ability to work independently and collaboratively in a multidisciplinary engineering environment.
• Experience with project management tools and software.
• Knowledge of industry best practices and trends.

Skills

• Proficiency in process simulation software (e.g., Aspen Plus, HYSYS).
• Experience with project management software (e.g., Microsoft Project, Primavera).
• Strong understanding of environmental regulations and their impact on process design.
• Ability to manage multiple projects simultaneously and meet deadlines.

Benefits

NorthStar Energy Services offers a competitive compensation package, including a comprehensive benefits program, a 401(k) plan with immediate matching, and opportunities for career advancement. We are an Equal Opportunity Employer and provide a supportive and inclusive work environment.