{"id":3411879,"url":"https://alion.io/job/commonwealth-fusion-systems-staff-process-engineer","title":"Staff Process Engineer","company":{"id":8705,"name":"Commonwealth Fusion Systems","domain":"cfs.energy","url":"https://alion.io/company/commonwealth-fusion-systems","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Lever","truth_index":{"grade":"A","score":85,"open_postings":5,"ghost_share":0,"stale_share":0.6,"repost_share":0,"time_to_fill_p50_days":54,"computed_at":"2026-11-05T05:54:30Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"staff","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Devens, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":152000,"max":230000,"currency":"USD","period":"year","gross":null,"usd_annual":230000},"salary_estimate":null,"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"ASME NQA-1","optional":false}],"status":"live","first_seen_at":"2026-10-28T16:58:01Z","employer_posted_date":"2026-10-28","last_verified_at":"2026-11-05T16:01:55Z","board_verified":true,"closed_at":null,"days_open":8,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":8},"description":"Join the power movement as a Staff Process Engineer\nCFS is looking for a Staff Process Engineer with deep chemical engineering fundamentals and extensive experience scaling up, commissioning, and operating systems in large industrial facilities (e.g., power generation, LNG, petrochemicals, or cryogenics). You excel at navigating loosely-defined outcomes, translating fundamental requirements into practical industrial systems, and guiding complex designs from early concepts through Front-End Loading (FEL), detailed engineering, construction, and operation.\nFusion power plants bring together technologies that traditionally span multiple industries. At CFS, you will work across cryogenics (nitrogen and helium), power generation (steam), molten salts (FLiBe), fueling (deuterium-tritium), gas processing, vacuum systems, and utilities. Acting as a domain expert, you will apply real world, hands-on experience to build process design bases from scratch for ambiguous projects, develop heat and material balances, size equipment, own P&IDs, lead HAZOPs, support start-up, and troubleshoot operating systems.\nWhat you'll do:\nOwn the process engineering scope for complex systems with loosely-defined outcomes, guiding them from early concept through operation with near complete independence\nTranslate fundamental engineering requirements into commercially viable systems, navigating semi-ambiguous challenges to develop process design bases, operating envelopes, PFDs, heat/material and utility balances, P&IDs, and process datasheets\nApply chemical engineering fundamentals (thermodynamics, phase equilibrium, fluid mechanics, heat and mass transfer, transport phenomena, reaction engineering, separations, and process control) to resolve complex technical challenges and define operating boundaries\nDevelop steady-state and dynamic process models using engineering analysis to guide process design, system architecture, and equipment selection\nSize, specify, and evaluate process equipment, working directly with suppliers, fabricators, and internal multidisciplinary teams to evaluate technical tradeoffs (performance, safety, cost)\nDrive engineering through a phase-gated design process, progressively maturing systems from conceptual to engineering definition\nLead process safety activities, including HAZOPs, design reviews, and relief/depressurization studies, and develop control philosophies and interlocks in collaboration with controls engineers\nSupport field execution by generating detailed work and commissioning plans, test procedures, and start-up strategies, actively participating in system commissioning and performance testing\nTroubleshoot operating equipment using first-principles engineering and field data, translating lessons learned into process improvements, new tools, and department policies\nProvide technical leadership, manage medium-to-large project risks by driving solutions, and mentor less-experienced engineers on complex process engineering problems\nWhat we're looking for:\nBachelor’s degree in Chemical Engineering (or closely related discipline)\n10+ years of relevant industrial process engineering experience (potentially fewer if a PhD), or equivalent demonstrated depth of experience\nDemonstrated deep domain expertise (or broad expertise across domains) with a proven ability to independently own complex, semi-ambiguous work, seeking support only when needed\nStrong command of chemical engineering fundamentals and a proven track record taking systems through a structured FEL or phase-gated development process\nExperience scaling up loosely-defined process requirements into commercial-scale equipment and facilities\nDeep expertise developing core process engineering deliverables (design bases, PFDs, P&IDs, heat/material balances) and sizing/selecting industrial process equipment\nHands-on experience commissioning, operating, and troubleshooting physical equipment alongside operators, using field observations to diagnose performance\nProficiency with process simulation tools (e.g., EcoSim, Aspen HYSYS/Plus, AVEVA) and extensive experience applying industry codes and standards (such as ASME B31.3,ASME BPVC Section VIII, API 520/521) to establish process design boundaries, fluid service classifications, operating envelopes, and relief/depressurization cases\nStrong background in process safety, hazard identification and risk analysis (e.g., HAZOP), and relief system design\nExperience integrating cross-functional engineering disciplines and working directly with vendors, EPC organizations, or construction contractors\nAbility to independently manage medium risks, drive solutions for larger project risks, and exercise strong engineering judgment to ensure practical, commercially viable designs\nValues that align with our company’s values of integrity, execution, impact, and self-critique\nBonus points for:\nExperience with large-scale cryogenic systems (particularly supercritical or liquid helium) and industrial high-vacuum systems\nBackground in large-scale process facilities (power generation, petrochemical, LNG, industrial gases, nuclear)\nExpertise in steam systems, molten salt systems, or industrial gas processing (purification, separation, fueling)\nExperience with large-scale utilities (cooling water, chilled water, compressed/instrument air, nitrogen)\nTrack record of scaling first-of-a-kind technologies from pilot/demonstration scale to commercial operation\nExperience with dynamic process simulation and consequence analysis\nLicensed as a Professional Engineer\nMust-have requirements:\nAbility to lift up to 50 lbs occasionally\nPerform activities such as stooping, climbing, typing, standing, and sitting for extended periods of time\nWillingness to occasionally travel or work required nights/weekends/on-call, including occasional travel to suppliers, contractors, or operating facilities\nWillingness and ability to work hands-on in industrial, construction, commissioning, and operating environments\nDedication 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","description_format":"text","description_chars":6183,"description_truncated":false,"requirements":{"experience_years_min":10,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Nuclear Energy","Nuclear Engineering"],"lifecycle":[{"event":"open","at":"2026-10-28T18:11:57Z"}],"visa":[],"liveness":{"score":90,"band":"hot","label":"Hiring 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