Senior Mechanical Engineer - Thermo​/Fluid Systems

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 is a senior individual contributor position, providing technical leadership in advanced engineering analysis, condition assessment, reverse engineering, and lifecycle evaluation of steam and gas turbine systems and associated components.

• Perform advanced thermal and structural stress analyses of turbo machinery 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, and performance characteristics, generating 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.

• Bachelor or Master degree in Mechanical Engineering or a related discipline.
• 7–10 years of progressive experience in turbo machinery 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 turbo machinery operation, thermodynamics, fluid mechanics, fracture mechanics, fatigue, and finite element methods.
• Advanced computer skills, including Microsoft Excel; experience with Mathcad, SQL, and scripting (VBA or similar) is a plus.
• Excellent analytical, problem‑solving, and written and verbal communication skills.
• Professional Engineer (PE) license preferred or willingness to pursue licensure.
• This position could be re‑coded for a suitable candidate with more experience and subject matter expertise.

The expected salary range for this role is $113,670 – $153,800 in San Jose, CA; $96,930 – $130,100 in Denver, CO. Exact pay will be commensurate with experience and location.

Certain positions at SIA may require access to information and technology subject to Export Administration Regulations 15 CFR 730‑774, including those of the US Department of Energy (DOE) in 10 CFR 810 and Nuclear Regulatory Commission (NRC) 10 CFR Part 110. Hiring decisions for such positions must comply with these regulations and may result in SIA limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List.

SIA is an equal‑opportunity employer.