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Zachry Group

Senior Process Engineer

Downers Grove, IL, United States

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Job details

Posting language: English
Posted: Nov 2, 2026

Original job description

Zachry Engineering Corp (ZEC) is currently building a pool of Senior Process Engineers with a background in Power Generation Combined Cycle to support our Downers Grove, IL office. The Senior Process Engineer will be responsible in the design office for routine engineering and design tasks of the assigned projects based on specific and detailed instructions received from the assigned supervisor as to the required tasks and results expected.

Responsible for developing Heat and Mass Balance for Combined Cycle Power Projects
Other duties as assigned
Responsible for developing process flow diagrams (PFD), piping and instrumentation diagrams (P&ID), and Process/Mechanical Equipment Datasheets
Responsible for sizing and rating various equipment like pumps, horizontal and vertical vessels, heat exchangers, and air coolers.
Responsible for performing hydraulic analysis and calculations for piping systems. Experience to include evaluating systems involving single phase, two phase, slurries, water hammer, slug flow, and distribution networks. Tools required should range from spreadsheet through rigorous software evaluations.
Translate project design basis requirements, client specifications, and contract documents into definable process tasks
Support Zachry quality program, ensuring proper quality checks and verifying proper documentation of input data.
Responsible for engineering and design of the Process engineering scope of assigned projects‎. ‎Independently evaluates, ‎selects, ‎and applies standard engineering techniques, ‎procedures, and criteria.
Support projects as an individual contributor. As needed, supervise, coordinate, and review work of a small team of engineers to accomplish project or department objectives.
Participate in various client Process Hazard Analysis reviews (i.e. risk review, HAZID, HAZOP/LOPA).
Responsible for design of relief system including contingency analysis, relief valve sizing, flare header design, and flare header analysis.
Present technical information to peers and/or clients for review and comment.
Analyze problems and take appropriate action to ensure continuous and reliable operation of equipment and systems.
Evaluate equipment and process to ensure compliance with safety and environmental regulations.
Coordinate with offshore High Value Engineering Center for engineering execution.
Must maintain active status in a drug and/or alcohol testing consortium.
Bachelor’s Degree in Chemical or Mechanical Engineering 15+ years of experience working as a Process / Mechanical Engineer in industries such as Oil Refining, Gas Processing, Power, or Chemical industries; 7+ years working in Power, refining/gas processing or similar PSM regulated industries; 5+ years working in an Engineering firm as a Process / Mechanical engineer
Comprehensive understanding of processes typically seen in Power / Process plants
Some travel (<25% expected) including visits to client sites with walkdowns in industrial environments; full compliance with site safety requirements and adhering to Zachry and client safety policies is essential
Experience applying standard engineering techniques, ‎procedures, and design criteria to ensure properly designed systems with accurate documentation and designs compliant with safety and environmental regulations.
Experience in PFD. P&ID and Equipment Datasheet development
Proficient in H&MB development, equipment and instrumentation process specification and performing hydraulic analysis. Strong background in the development of HMB for Combined Cycle Projects preferred.
Knowledge of Performance Guarantees including emissions compliance
Experience in the specification of fixed and rotating equipment including STG, CTG, and HRSG
Strong knowledge of ASME and API 520/521 with proficiency designing relief devices and associated collection headers
Excellent Communication Skills (Active Listening, Verbal, and Written)
Excellent Attention to Detail – in own work as well as demonstrated in checking work of others
Proven history of meeting schedule commitments and planning resources required
Proficient with Process modeling software (AspenTech suite preferred)
Demonstrated desire to learn new technologies and apply learnings to current projects

Preferred Qualifications

Licensed Professional Engineer
Experience Utilizing the Thermoflow suite of Software Tools to develop HMB and TIC estimates
Knowledge and/or experience in EPC Power business
Experience with designing OSBL/Utility scopes required to support Licensor packages
Past exposure to environmental permitting and citing studies
Active member of professional organizations/committees

Physical Demands Employee will be required to communicate in person, via telephone, email, use of arm/hand steadiness, manual dexterity, finger dexterity, multi limb coordination, oral expression, and comprehension. May be required to lift, carry, and move objects safely. Work Environment Will work in a general office environment. Capable of operating and functioning in a fast-paced work environment. Must possess a vision (corrected or uncorrected) that allows for clear visibility from a distance of 20 inches or less. The above description covers the fundamental responsibilities of the Senior Process Engineer position. It shall not be construed as a complete listing of all miscellaneous, incidental, or similar duties which may be required from day-to-day. Zachry Group is dedicated in providing a Safe and Drug Free work environment; and is an Equal Opportunity Employer.

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