Senior Mechanical Engineer - Thermo/Fluid Systems

Structural Integrity Associates (SIA) is seeking a Senior Mechanical Engineer with expertise in thermo-fluid systems to join our Energy Services Group within the Turbine Generator Services team. This role provides technical leadership in advanced engineering analysis and lifecycle evaluation of steam and gas turbine systems, requiring collaboration with project managers and multidisciplinary teams, along with periodic travel for field support.

Responsibilities:

• Perform advanced thermal and structural stress analyses of turbomachinery components, gas and steam turbine rotors, and auxiliary equipment using classical methods and finite element analysis tools such as ANSYS and Abaqus
• Develop and apply system and component level thermo-fluid and performance models for steam and gas turbines, including Digital Twin models (AxStream) for predictive analytics and lifecycle management
• Conduct ASME Code evaluations and ensure compliance with applicable industry standards and best practices
• Utilize thermo-fluid simulation tools (e.g., AxStream, ANSYS Fluent, STAR-CCM+) to evaluate flow behavior, operating conditions, performance characteristics, and generate boundary conditions for subsequent Thermo/Structural analysis and remaining life assessment
• Support nondestructive examinations and condition assessments, including metallurgical replication, hardness testing, ultrasonic inspection, and related techniques
• Provide technical input for failure investigations, root cause evaluations, and remaining life assessments
• Prepare clear, well-structured technical reports and client-facing presentations summarizing analyses, findings, and engineering recommendations
• Contribute to internal research and development initiatives focused on automation, AI-enabled methodologies, and continuous improvement of analysis techniques
• Support project managers in the execution of complex, multi-disciplinary engineering projects
• Lead or independently manage technical tasks and small-to-moderate scale projects as appropriate
• Ensure technical quality through peer review, documentation, and adherence to internal standards
• Maintain financial responsibility and comply with company guidelines related to project execution, expenses, and scheduling
• Support project managers in the execution of complex, multi-disciplinary engineering projects
• Lead or independently manage technical tasks and small-to-moderate scale projects as appropriate
• Ensure technical quality through peer review, documentation, and adherence to internal standards
• Maintain financial responsibility and comply with company guidelines related to project execution, expenses, and scheduling
• Approximately 25% travel annually, primarily associated with power plant outage seasons (spring and fall), field inspections, and reverse engineering activities at client or SIA facilities
• Occasional field work in operating power plant environments, which may include exposure to heat, noise, and confined space
• Ability to comply with annual respirator fit testing and drug-free workplace requirements

Requirements:

• Bachelor or Master degree in Mechanical Engineering or a related discipline
• 7–10 years of progressive experience in turbomachinery engineering, including steam and gas turbine design, analysis, or field engineering
• Proficiency in finite element analysis (FEA) tools (e.g., ANSYS, Abaqus) and thermo-fluid simulation software
• Strong understanding of turbomachinery operation, thermodynamics, fluid mechanics, fracture mechanics, fatigue, and finite element methods
• Advanced computer skills, including Microsoft Excel
• Excellent analytical, problem-solving, and written and verbal communication skills
• Ability to comply with annual respirator fit testing and drug-free workplace requirements
• Professional Engineer (PE) license preferred or willingness to pursue licensure
• Experience with Mathcad, SQL, and scripting (VBA or similar) is a plus