Senior Process Engineer
Commonwealth Fusion SystemsDevens, MA
Full Time
Posted September 16, 2026
$110k - $185k
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Job Description
About Commonwealth Fusion Systems:
Key Responsibilities
- Own process engineering scope for complex systems from early concept through design, construction, commissioning, start-up, and operation
- Develop process concepts and translate fundamental engineering requirements into practical, commercially viable industrial systems
- Develop process design bases, operating envelopes, design cases, process flow diagrams (PFDs), heat and material balances, utility balances, P&IDs, equipment lists, line lists, and process datasheets
- Apply chemical engineering fundamentals including thermodynamics, phase equilibrium, fluid mechanics, heat and mass transfer, transport phenomena, reaction engineering, separations, process dynamics, and process control
- Develop steady-state and dynamic process models and use engineering analysis to guide system architecture, equipment selection, and operating strategy
- Size and specify process equipment including pumps, compressors, blowers, heat exchangers, vessels, columns, piping systems, control valves, relief devices, and other unit operations
- Lead process engineering through Front-End Loading (FEL) and progressively mature systems from conceptual design through process definition and engineering definition
- Evaluate process alternatives and technical tradeoffs considering performance, safety, reliability, operability, maintainability, capital cost, and lifecycle cost
- Develop equipment and package specifications, technically evaluate vendor proposals, and work directly with equipment suppliers and fabricators
- Lead or contribute to process safety activities including HAZOPs, design reviews, relief and depressurization studies, consequence evaluations, and development of safeguards
- Develop process control philosophies, operating sequences, alarm requirements, permissives, interlocks, and operating limits in collaboration with controls engineers and operators
- Perform multidisciplinary technical reviews to ensure that systems are safe, operable, maintainable, and capable of achieving their intended process function
- Support procurement, fabrication, construction, installation, inspection, and field engineering, including field walkdowns and resolution of design and construction issues
- Develop commissioning plans, test procedures, operating procedures, and start-up strategies and participate directly in commissioning, start-up, performance testing, and operation of process systems
- Troubleshoot operating equipment and processes using first-principles engineering, process data, field observations, and structured process investigations
- Capture lessons learned from construction, commissioning, and operation and translate them into improvements in process safety, reliability, operability, maintainability, performance, engineering standards, and future designs
- Provide technical leadership and mentor less-experienced engineers on complex process engineering problems
Requirements
- Bachelor’s degree in Chemical Engineering (or closely related discipline)
- 7+ years of relevant industrial process engineering experience, or equivalent demonstrated depth of experience
- Strong command of chemical engineering fundamentals including mass and energy balances, thermodynamics, phase equilibrium, fluid mechanics, heat and mass transfer, transport phenomena, unit operations, and process dynamics and control
- Experience designing process systems for large-scale industrial facilities
- Demonstrated experience taking process systems through a structured FEL or equivalent stage-gated project development process, from concept and process definition through detailed engineering and execution
- Experience with process scale-up, technology scale-up, or translating process requirements into commercial-scale equipment and facilities
- Demonstrated experience developing core process engineering deliverables including process design bases, heat and material balances, PFDs, P&IDs, equipment specifications, datasheets, and process calculations
- Experience sizing, specifying, and selecting industrial process equipment
- Hands-on experience operating, commissioning, starting up, performance testing, and troubleshooting industrial process systems and physical equipment
- Experience working directly with operators and technicians and using operating data and field observations to diagnose process performance
- Experience with process simulation and analysis tools such as EcoSim, Aspen HYSYS, Aspen Plus, AVEVA Process Simulation, or equivalent
- Experience with process safety and hazard analysis, including HAZOP or equivalent methodologies
- Experience with relief system design and overpressure protection
- Experience working with and integrating other engineering disciplines including mechanical, piping, instrumentation and controls, electrical, safety, operations, and construction
- Experience working directly with equipment vendors, fabricators, EPC organizations, or construction contractors
- Familiarity with applicable process industry codes and standards, including ASME B31.3 and ASME BPVC Section VIII
- Ability to clearly express and critique technical ideas, assumptions, risks, and tradeoffs
- Strong engineering judgment and the ability to recognize when analytical or simulation results do not make physical sense
- Attention to detail with an emphasis on practical, elegant, and commercially viable engineering solutions
- Values that align with our company’s values of integrity, execution, impact, and self-critique
- Ability to lift up to 50 lbs occasionally
- Perform activities such as stooping, climbing, typing, standing, and sitting for extended periods of time
- Willingness to occasionally travel or work required nights/weekends/on-call, including occasional travel to suppliers, contractors, or operating facilities
- Willingness and ability to work hands-on in industrial, construction, commissioning, and operating environments
- Dedication to safety to mitigate hazards that may include heat, cold, noise, fumes, strong magnets, lead, high voltage, high current, pressure systems, vacuum systems, hazardous materials, and cryogenics
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