Sr Design Engineer Jobs in Reston, VA (NOW HIRING)

The Senior Design Electrical Engineer is responsible for the end-to-end electrical engineering design scope associated with the conversion of a crude oil refinery into a fuel terminal in Papua New Guinea. This encompasses the decommissioning and isolation of crude processing electrical systems, the greenfield and brownfield electrical design for the new fuel terminal facility, and active support throughout construction and commissioning. The role requires a thorough knowledge of PNG regulatory requirements, Australian Standards, IEC standards, and hazardous area design in petroleum environments.

Power system design & analysis

• Develop single-line diagrams (SLDs), load schedules, and cable routing drawings for the converted fuel terminal, accounting for the tropical PNG environment (ambient temperature, humidity, altitude, UV exposure).
• Assess/Modify existing HV/LV transformers, switchgear, MCCs, UPS, emergency standby generators, and capacitor banks appropriate for terminal operations (loading pumps, metering skids, tank farm auxiliaries, truck loading gantries).
• Perform load flow, short-circuit, protection coordination, and arc flash studies using ETAP, SKM PowerTools, or equivalent; produce detailed arc flash risk assessment reports per IEEE 1584.
• Design lighting systems (including emergency and escape lighting) for outdoor and indoor terminal areas, incorporating tropical climate factors (UV-stabilized fittings, IP65 minimum for outdoor).
• Design earthing, bonding, and cathodic protection systems in accordance with IEC 62305 and API RP 2003, with particular attention to static control at loading arms and road tanker interfaces.
• Specify surge protection devices (SPDs) and lightning protection systems suitable for the high-lightning-incidence environment of PNG.

Hazardous area classification

• Produce, review, and sign off hazardous area classification (HAC) drawings for all terminal zones (storage tank vents, loading arms, pump areas, drain pits, road tanker gantries) in accordance with IEC 60079-10-1 and API RP 505.
• Select and specify IECEx-certified Ex-rated electrical equipment (Ex d, Ex e, Ex nA, Ex p) consistent with zone classification and group/temperature class of the stored products (gasoline, diesel, jet fuel, avgas).
• Maintain the Ex equipment register and ensure equipment selection records are traceable for DPE submission and audit purposes.
• Support HAZOP and HAZID reviews from an electrical and area classification perspective; prepare and close out associated electrical action items.

Decommissioning & demolition engineering

• Develop detailed electrical isolation, de-energization, and demolition packages for crude processing units being taken out of service, including lock-out/tag-out (LOTO) procedures.
• Identify and engineer electrical tie-in points between retained infrastructure (substation, distribution boards, cable routes) and new terminal equipment.
• Prepare cable disconnection and reinstatement schedules, and co-ordinate with operations for planned outage windows.
• Ensure all decommissioning activities comply with PNG WHS Act 2022 and site safety management plan.

I&C and control system interface

• Co-ordinate with the Instrumentation and Control discipline on instrument power supplies, marshalling cabinet design, and MCC intelligent device integration.
• Specify and review motor control logic, VFD applications, soft-starter specifications, and ESD/SIS electrical interface requirements.
• Provide electrical input to the fire and gas detection system, including power supply, cable segregation, and solenoid valve loop drawings.
• Review I/O schedules and ensure power supply sizing for DCS, RTU, and SCADA field equipment.

Design deliverables & documentation

• Produce and check all electrical deliverables to project schedule: SLDs, cable schedules, equipment layouts, conduit and cable tray routing, wiring diagrams, termination schedules, hook-up drawings, and equipment datasheets.
• Maintain and update the electrical equipment list, cable register, motor list, and instrument index throughout all project phases.
• Prepare technical bid evaluations (TBEs) and purchase requisitions for electrical equipment and bulk materials; review vendor documentation for compliance.
• Issue deliverables through the project document management system (EDMS); manage review and comment cycles with client and third-party verifiers.

Construction & commissioning support

• Provide technical query (TQ) and request for information (RFI) responses during construction; conduct site visits as required.
• Prepare and review electrical pre-commissioning and commissioning procedures; support energisation and loop check activities.
• Assist in the preparation of as-built documentation, final dossiers, and regulatory submissions to PNG DPE and Electrical Inspector.
• Participate in final safety walks and pre-startup safety reviews (PSSRs) for electrical systems.

Requirements:

• Registration as a Licensed Electrical Engineer with the PNG Electrical Inspector's office is required before commencement of site activities. The employer will support the candidate in obtaining PNG registration where this is not already held. Chartered Engineer status (IET, Engineers Australia, or equivalent international body) is desirable.
• Bachelor's degree in Electrical Engineering (or equivalent recognized qualification). Masters degree preferred
• Minimum 10 years of detail design experience in oil & gas, petrochemical, or downstream refining / terminal projects. Experience on a refinery conversion, terminal construction, or tank farm project is preferred.
• Demonstrated competency in power system analysis software: ETAP, SKM PowerTools, or equivalent. Experience with Smart Plant Electrical (SPE) or AVEVA E3D electrical module preferred
• Solid knowledge and application of IEC 60364, IEC 60079, AS/NZS 3000, and PNG Electrical Installation Act. IECEx CoPC (Certificate of Personnel Competence) or equivalent is preferred.
• Proven experience in hazardous area classification and IECEx / ATEX Ex-rated equipment selection. IECEx CoPC (Certificate of Personnel Competence) or equivalent is a plus.
• Competency in AutoCAD, MicroStation, or equivalent for drawing production. Exposure to functional safety (IEC 61511) from an electrical design perspective is preferred.
• Experience reviewing vendor submittals and conducting technical bid evaluations. Knowledge of API RP 2003 (static, lightning, stray current protection) is a plus.
• Ability to work in a remote project environment or ability to travel to PNG site. Prior experience working in PNG, Pacific Island, or similarly remote tropical locations is preferred.