Process Mechanical Engineer, Senior (Process Controls)
Confirmed on the employer's own hiring board on Oct 7, 2026. First seen by Alion on Jul 24, 2026.
What you will be doing in the role of Process Mechanical Engineer, Senior:
Process Control System Design
Lead the development of process control strategies for industrial process systems and fuel-burning equipment.
Develop, review, and seal engineering design documentation:
P&IDs
Instrument Indexes
Control Narratives
Functional Descriptions
Operating Philosophies / Procedures
Cause & Effect Matrices
Logic Diagrams / Control Schematics
Alarm and Interlock Philosophies
Develop startup, shutdown, permissive, bypass, and abnormal operating strategies.
Develop quality documentation, including test plans and commissioning procedures.
Define instrumentation, controls, and safety system requirements.
Work closely with controls and automation teams to support PLC, HMI, DCS, SIS, and BMS implementation.
Participate and support in system integration, testing, commissioning, startup, and troubleshooting activities.
Process Safety & Functional Safety
Participate in hazard reviews including HAZOP, Process Hazard Analysis (PHA), and risk assessments.
Develop and review safety shutdown strategies and protective system requirements.
Identify process hazards and define mitigation strategies.
Establish alarm management and operator response strategies.
Ensure process control systems are designed with a strong focus on safety, reliability, maintainability, and operability.
Regulatory Compliance & Engineering Design Documentation
Prepare and review engineering submittal packages required for regulatory approvals and field acceptance activities, including:
Regulatory application and submission forms completion
Code compliance assurance letters
Engineering design documentation
Support regulatory approval and customer acceptance processes.
Interface directly with customers, consultants, vendors, and regulatory authorities.
Ensure designs comply with applicable codes, standards, and regulatory requirements.
Customer & Technical Leadership
Serve as the primary technical resource for process control and safety-related aspects of projects.
Support proposal development and concept engineering activities.
Review engineering deliverables prepared by internal and external resources.
Develop trusted relationships with customers and provide technical guidance throughout project execution.
Support business development efforts through technical presentations, customer meetings, and solution development workshops.
Mentorship & Continuous Improvement
Mentor junior engineers and technical staff.
Develop and maintain engineering standards, templates, and design practices.
Support the development of internal standards related to:
Burner Management Systems (BMS)
Combustion Control Systems (CCS)
SAMA Diagrams
Process Safety Documentation
Drive continuous improvement initiatives that improve engineering quality, productivity, and consistency.
Knowledge and skills required for the role:
Bachelor's Degree in Engineering (Chemical, Electrical, Mechanical, Process Automation, or related discipline).
Professional Engineer (P.Eng.) designation in good standing.
10+ years of experience in process controls, industrial automation, process engineering, or related industrial environments.
Demonstrated experience developing and reviewing:
P&IDs
Instrument Indexes
Control Narratives
Functional Descriptions
Operating Philosophies / Procedures
Cause & Effect Matrices
Logic Diagrams / Control Schematics
Alarm and Interlock Philosophies
Experience supporting multidisciplinary engineering projects from concept through commissioning.
Strong understanding of process safety principles and industrial control systems.
Excellent communication, troubleshooting, and customer-facing skills.
Preferred QualificationsDirect experience with fuel-burning equipment, combustion control systems, and CSA B149.3 field approval requirements is highly desirable; however, candidates with strong process control, functional safety, industrial automation, or process safety backgrounds will also be considered.
Experience developing engineering deliverables for fuel-burning appliances, industrial combustion systems, fired equipment, thermal processes, or burner management systems.
Experience applying requirements contained within:
CSA B149.3
TSSA Fuels Safety requirements
TSSA Field Approval processes
NFPA 85
NFPA 86
ISA standards
IEC 61511 and functional safety principles
Experience preparing engineering documentation to support field approvals, regulatory reviews, AHJ acceptance, and code compliance.
Experience with Burner Management Systems (BMS), Combustion Control Systems (CCS), Safety Instrumented Systems (SIS), PLCs, and DCS-based control architectures.
Experience facilitating or participating in HAZOP, SIL, PHA, or other process hazard and risk assessment studies.
Experience with boilers, process heaters, furnaces, thermal oxidizers, incinerators, kilns, dryers, flare systems, or other fuel-fired process equipment.
Experience with hydrogen systems, renewable fuels, landfill gas, biogas, syngas, refinery gas, or other alternative fuel applications.
Familiarity with other codes impacting the installation of Natural Gas (CSA B149.1) and Oil systems (CSA B139)