Senior Process Engineer

Are you a seasoned Process Engineer who thrives on solving complex technical challenges and seeing projects move from concept to reality? At Sky Eye Measurement, you'll play a pivotal role in designing and delivering transloading terminals and midstream facilities that support the safe and efficient movement of LPGs, NGLs, crude oil, refined products, and specialty chemicals. Working alongside multidisciplinary teams, clients, consultants, and operations personnel, you'll lead process engineering efforts across a diverse portfolio of projects, combining technical expertise, innovation, and practical execution to bring our clients' visions to life.

PURPOSE:The Senior Process Engineer leads the development and execution of process engineering deliverables for transloading terminals and midstream facilities, ensuring safe, high-quality, operable, and compliant designs.

This role is accountable for the process scope from concept through commissioning, including process simulations, heat and material balances, PFDs, P&IDs, equipment specifications, and relief system design. As the process discipline lead, the Senior Process Engineer provides technical oversight, exercises sound engineering judgment, ensures deliverable integrity, and mentors junior engineers.

KEY CHARACTERISTICS & COMPETENCIES:

• Solutions-oriented with a positive, can-do mindset.
• Committed to quality, process safety, and health & safety excellence.
• Strong communication and technical writing skills.
• Organized and effective at creating structure in dynamic environments.
• Sound engineering judgment with the ability to make decisions and appropriately escalate issues.
• Strong collaborator who works effectively with multidisciplinary teams, clients, vendors, and operations personnel.
• Skilled at managing multiple priorities and concurrent projects while meeting commitments.
• Proven ability to mentor, coach, and develop junior engineers and share technical knowledge.

RESPONSIBILITIES:

Process Design & Analysis

• Develop heat and material balances, process flow diagrams and process descriptions for new facilities and facility modifications.
• Build and maintain steady-state process simulations for transfer, storage, vapour handling, compression, separation and liquids conditioning systems.
• Perform equipment sizing and rating for pressure relief valves (PRVs), pressure safety valves (PSVs), thermal relief valves (TRVs), rupture discs and vacuum relief devices, as well as separators, heat exchangers, fired equipment, pumps, compressors, tanks and vessels.
• Perform relief device sizing for all governing scenarios including fire case, blocked outlet, thermal expansion of blocked-in liquid lines, control valve failure, tube rupture and loss of cooling; document scenario selection and rated versus required capacity.
• Develop and issue process equipment datasheets and technical specifications for procurement, including relief device datasheets and set pressure schedules.
• Perform hydraulic calculations for piping, headers, transfer lines and flare systems, including line sizing, pressure drop, NPSH and pump/compressor duty analysis.
• Design pressure relief, vapour handling and flare systems in accordance with API 520, 521, 526 and 2000; specify relief headers, knockout drums and disposal routing.
• Perform hydraulic surge and transient analysis for loading and unloading lines, including valve closure, pump trip and emergency shutdown scenarios, and specify surge mitigation.
• Develop control philosophies, cause and effect matrices, shutdown keys and operating philosophies.
• Perform process debottlenecking, capacity studies, energy optimization and troubleshooting of existing facilities.

Transloading & Terminal Systems

• Design rail and truck loading and unloading racks, including loading arm and hose selection, drop tube design, transfer pump and compressor sizing, and fill rate and cycle time analysis.
• Determine transfer rates and connection sizing to meet target rail car and truck turnaround times, including spot counts, manifold arrangement and simultaneous transfer scenarios.
• Design vapour handling systems including vapour return and balancing lines, vapour recovery units, thermal oxidizers and flare or combustion disposal, and calculate vapour generation and displacement rates.
• Perform boil-off, flash and weathering calculations for pressurized LPG and NGL service, including tank car and bullet pressure profiles across ambient conditions.
• Specify overfill protection, high-level and high-pressure shutdown, emergency shutdown systems, breakaway couplings and Deadman controls for transfer operations.
• Design thermal relief protection for blocked-in liquid transfer lines, loading arms and hoses, a governing relief case in transloading service.
• Address static electricity generation and dissipation, bonding and grounding requirements, and inerting or purging requirements in accordance with API RP 2003.
• Design tank farm and storage systems including bullets, pressure vessels and atmospheric tanks, with secondary containment, drainage and blowdown provisions.
• Develop custody transfer and metering philosophies, including meter selection, proving requirements and measurement uncertainty considerations.
• Establish product segregation, compatibility and dedicated service requirements, and develop line clearing, purging, cleaning and changeover procedures for multi-product operations.
• Develop process input to rail spur and truck bay layouts, including spacing, setbacks, access and egress, and separation distances between transfer points and ignition sources.
• Support facility siting and consequence analysis, including release, dispersion and fire and explosion scenario input for terminal layout decisions.

P&ID and Deliverable Development

• Develop and maintain P&IDs from concept through issued-for-construction, including instrumentation, control loops and safeguarding.
• Define line list data, valve requirements, insulation requirements and process design conditions for piping specifications.
• Develop utility balances and specify utility systems including instrument air, fuel gas, nitrogen, cooling and heating media.
• Review and approve process deliverables prepared by other engineers and designers, applying discipline check and squad-check procedures.

Technical Leadership & Review

• Act as the process discipline technical authority on assigned projects and serve as the primary technical point of contact for the client.
• Provide technical direction, review and mentorship to intermediate and junior process engineers and to the design group.
• Lead or participate in HAZOP, LOPA, SIL determination, PHA and design review sessions, and close out resulting action items.
• Review vendor proposals and equipment submittals for technical compliance and integration into the overall process design.
• Identify and communicate technical risks, assumptions and design gaps to project management early and clearly.

Project & Client Support

• Develop process scopes of work, deliverable lists, engineering hour estimates and schedules for proposals and executing projects.
• Support conceptual and feasibility studies, options analyses, and Class 5 through Class 3 cost estimate development.
• Coordinate with piping, mechanical, electrical, instrumentation, structural and civil disciplines to deliver an integrated design.
• Support procurement, construction, pre-commissioning, commissioning and startup, including first-fill, initial transfer operations, field troubleshooting and performance testing.
• Develop operating procedures and support operator training for transfer, changeover and emergency response scenarios.
• Attend client meetings, site visits and regulatory discussions, and present technical positions clearly to technical and non-technical audiences.
• Track progress against budgeted hours, identify scope changes, and support change management with the project manager.

Standards, Safety & Compliance

• Apply applicable codes and standards including ASME Section VIII, ASME B31.3 and B31.4, API 520/521/526/2000, CSA B51 and ABSA requirements.
• Apply transloading and terminal standards including NFPA 30, NFPA 58, API RP 2003, API MPMS for measurement, and CSA B620 and B622 for transport of dangerous goods equipment.
• Apply Transportation of Dangerous Goods (TDG) regulations and associated rail requirements, including tank car specifications such as TC/DOT-111, 112, 117 and 105 and applicable AAR and Transport Canada requirements.
• Apply provincial and federal regulatory requirements relevant to midstream and terminal facilities, including AER directives and environmental approvals where applicable.
• Embed inherently safer design principles, operability and maintainability into process design decisions.
• Maintain complete and auditable design basis documentation, calculations and assumptions registers.
• Contribute to the development and improvement of company engineering standards, templates, calculation tools and work processes.

Qualifications & Experience

• Bachelor's degree in Chemical Engineering, Process Engineering or a closely related discipline.
• Registered Professional Engineer (P.Eng.) with APEGA, or eligible for registration in the province of practice if registered elsewhere.
• Ten or more years of process engineering experience, with substantial experience in transloading terminals, tank farms, midstream facilities or liquids handling operations.
• Demonstrated ownership of process scopes from concept through detailed design, construction support and startup.
• Direct experience with rail and truck loading and unloading systems, including transfer equipment, vapour handling and terminal operations, is strongly preferred.
• Strong working knowledge of pressurized LPG and NGL service, crude and refined liquid handling, and multi-product terminal operations.
• Proven experience in relief system design — including PRV, PSV and thermal relief valve sizing, scenario development and relief documentation — and in flare and vapour disposal design.
• Familiarity with Transportation of Dangerous Goods requirements and rail tank car specifications as they constrain terminal process design.
• Experience leading or actively participating in HAZOP and process hazard analysis sessions.
• Experience with brownfield modifications and tie-ins to operating facilities, including constraints of live plant work.
• Consulting or EPC environment experience, including working to client specifications and managed engineering budgets, is preferred.

Software & Technical Skills

• Process simulation software such as Aspen HYSYS, Aspen Plus, VMGSim or ProMax.
• Relief and flare analysis tools such as Aspen Flare System Analyzer, or equivalent hand and spreadsheet methods; relief sizing per API 520 Part I.
• Hydraulic and line sizing tools; surge and transient analysis software such as AFT Impulse or Pipenet is an asset.
• Exchanger rating software such as HTRI is an asset.
• AutoCAD or AutoCAD Plant 3D familiarity sufficient to mark up and review P&IDs and layouts.
• Navisworks or equivalent for 3D model review and design coordination is an asset.
• Advanced Microsoft Excel for engineering calculations, data analysis and balance development.

Working Conditions

• Primarily office-based engineering work at a computer workstation.
• Periodic travel to client offices, plant sites and fabrication shops for design reviews, site visits, commissioning and startup support.
• Site work requires the use of personal protective equipment and compliance with client site orientation and safety requirements.
• Occasional overtime and extended site hours may be required during commissioning and to meet project milestones.

What We Offer

• Competitive salary commensurate with experience.
• Comprehensive health and dental benefits.
• Varied project work across multiple industries and client types.
• Support for continuing education, technical training and professional development.
• A collaborative team environment with meaningful technical ownership and direct client exposure.