Senior Turbomachinery Engineer, Structural Analysis & Design

Structural Integrity Associates is an engineering consulting firm serving the energy and infrastructure industries. The company is seeking a Senior Turbomachinery Engineer to provide technical leadership in structural analysis, condition assessment, reverse engineering, and lifecycle evaluation of steam and gas turbine systems. The role includes advanced FEA and Digital Twin development, technical project leadership, client support, and periodic field travel.

Responsibilities:

• Perform advanced thermo-mechanical and structural analyses of turbomachinery components, including gas and steam turbine rotors, blades, casings, and auxiliary equipment using FEA tools such as ANSYS
• Develop detailed 2D and 3D CAD models (axisymmetric and solid) of turbine components using SolidWorks or equivalent
• Conduct steady-state and transient thermal analyses (startup, shutdown, cyclic duty, load-following)
• Evaluate damage mechanisms including LCF, HCF, TMF, creep, creep-fatigue interaction, fracture mechanics, SCC, fretting, and stress rupture
• Perform fitness-for-service (FFS) and remaining life assessment (RLA) evaluations to support continued operation, uprates, and life extension
• Apply ASME, API, OEM, and other applicable industry codes and standards
• Support reverse engineering activities, including field dimensional capture, material characterization, and redesign improvements
• Develop and apply Digital Twin models integrating operating data, inspection findings, and analytical results
• Interpret inspection and NDE data, including UT, MPI/PT, metallurgical replication, hardness testing, and borescope inspections
• Provide technical input for failure investigations, root cause analyses, and risk assessments
• Prepare clear, well-structured technical reports and client-facing presentations summarizing findings and recommendations
• Support project managers in the execution of complex, multi-disciplinary engineering projects
• Serve as a technical lead on projects and provide mentorship to junior engineers
• Contribute to business development efforts, including proposal support and technical scoping
• Maintain strong client relationships and serve as a trusted technical advisor
• Lead or independently manage technical tasks and small-to-moderate scale projects
• Ensure technical quality through peer review, documentation, and adherence to internal standards
• Maintain financial accountability and comply with company guidelines for project execution, scheduling, and expenses
• Approximately 10% travel annually, primarily aligned with outage seasons, inspections, or special client support activities
• Occasional field work in power plants, industrial sites, or manufacturing environments
• Ability to work safely in environments involving heat, noise, elevated platforms, and confined spaces
• Compliance with client safety, training, and testing requirements

Requirements:

• • Bachelor's or Master's degree in Mechanical Engineering or related discipline
• • 10+ years of progressive experience in turbomachinery engineering (steam and/or gas turbines)
• • Strong proficiency in FEA tools (ANSYS Mechanical preferred)
• • Strong experience with CAD modeling (SolidWorks or equivalent)
• • Deep understanding of fatigue, creep, fracture mechanics, and high-temperature material behavior
• • Excellent analytical, problem-solving, and communication skills
• • Approximately 10% travel annually, primarily aligned with outage seasons, inspections, or special client support activities
• • Occasional field work in power plants, industrial sites, or manufacturing environments
• • Ability to work safely in environments involving heat, noise, elevated platforms, and confined spaces
• • Compliance with client safety, training, and testing requirements
• • Professional Engineer (PE) license preferred
• • Experience with AxStream, CFD tools, or automation tools (Python, VBA, SQL)