Consultant, Mechanical Turbomachinery Engineer

Description:
Structural Integrity Associates, Inc. (SIA) is seeking an experienced Consultant specializing in turbomachinery structural design and analysis, with a strong background in gas or steam turbines. Previous experience within the power generation, aerospace, or energy industries, particularly with an original equipment manufacturer (OEM) or independent service provider, is preferred.

The successful candidate will provide advanced technical expertise in thermal and structural analysis to lead the support and execution of engineering projects involving rotating equipment, reverse engineering, fitness-for-service evaluations, and remaining life assessments. This position will lead the development of analytical digital twin models using computer-aided design (CAD) and finite element analysis (FEA) tools to evaluate equipment performance under transient and steady-state operating conditions. These analyses will support the assessment of potential failure mechanisms, remaining service life, and appropriate inspection intervals.

This position requires collaboration with clients, multidisciplinary engineering teams, and senior technical personnel to support equipment condition assessments, reverse engineering, and lifecycle evaluations of rotating and stationary components.

Primary Responsibilities:

• Perform advanced finite element thermal and structural stress analyses of turbomachinery components using engineering software, including ANSYS and Abaqus, as required.
• Develop detailed 2D and 3D models of turbomachinery components and assemblies, including gas and steam turbine rotors and blades, to support engineering analysis and reverse engineering activities.
• Conduct applicable ASME Code evaluations and ensure engineering analyses comply with relevant industry standards and design criteria.
• Develop, maintain, and utilize analytical digital twin models of gas and steam turbines to support equipment performance evaluations, predictive analytics, and lifecycle management.
• Utilize thermodynamic and fluid dynamics software, including AxStream, Fluent, and STAR-CCM+, as required, to support performance and flow analyses.
• Integrate thermal and fluid simulation results, including boundary conditions developed using AxStream, into structural FEA models.
• Evaluate equipment operating conditions, including temperature distributions, stresses, strains, and material behavior, to assess potential failure mechanisms and remaining service life.
• Support the evaluation of nondestructive examination (NDE) results and equipment condition assessments, including metallurgical replication, hardness testing, and ultrasonic inspection techniques.
• Prepare and present detailed technical reports, engineering calculations, and recommendations to clients and internal stakeholders.
• Contribute to internal research and development initiatives focused on process automation, artificial intelligence applications, and improvements in engineering analysis methods and accuracy.

Leadership & Client-Facing Responsibilities:

• Provide technical leadership, guidance, and mentorship to junior engineers and analysts to support professional development and knowledge transfer.
• Serve as a primary technical point of contact for clients, ensuring effective communication of project objectives, deliverables, and engineering recommendations.
• Lead technical discussions, client meetings, and presentations to communicate project findings and support long-term client relationships.
• Collaborate with multidisciplinary teams and other SIA business units to develop engineering solutions that align with client needs and operational requirements.
• Provide technical oversight and support throughout project execution to ensure quality, accuracy, and timely delivery of engineering services.

Required Skills/Qualifications:

• Bachelor’s degree in mechanical engineering or a related engineering discipline.
• Minimum of 10 years of relevant professional engineering experience, including significant experience in turbomachinery structural design, analysis, or field service engineering support.
• Demonstrated technical expertise in gas or steam turbine design, structural analysis, and equipment evaluation.
• Proficiency in 2D and 3D modeling of turbomachinery components, including rotors and blades, using SolidWorks or comparable CAD software.
• Proficiency in finite element analysis software, including ANSYS or Abaqus, and experience with thermodynamic or fluid simulation software, including AxStream.
• Strong understanding of creep, fatigue, fracture mechanics, and finite element methods as they relate to equipment failure mechanisms and remaining life assessments.
• Demonstrated ability to independently lead complex engineering analyses, interpret technical results, and develop practical engineering recommendations.
• Advanced computer skills, including proficiency with Microsoft Excel and ability to automate/optimize processes via the use of AI tools.
• Strong analytical, problem-solving, organizational, and communication skills.
• Ability to provide technical leadership and collaborate effectively with clients, multidisciplinary engineering teams, and other technical professionals.

Preferred Qualifications:

• Master's degree or Ph.D. in Mechanical Engineering or a related engineering discipline.
• Previous experience within the power generation, aerospace, or energy industries.
• Experience working with original equipment manufacturers (OEMs) or independent service providers.
• Familiarity with gas and steam turbine operations, maintenance, and inspection practices.
• Experience with fitness-for-service evaluations, remaining life assessments, reverse engineering, and equipment condition assessments.
• Experience with Microsoft Access, SQL, and programming or scripting languages such as Python or VBA.
• Professional Engineer (PE) license or willingness to pursue professional licensure.

Travel & Work Conditions:

• Less than 10% annual travel, primarily involving occasional visits to power generation facilities during scheduled outage seasons or to client sites and maintenance, repair, and overhaul (MRO) facilities in support of engineering and reverse engineering activities.
• Occasional fieldwork in power plants, industrial facilities, or MRO facilities may involve exposure to elevated temperatures, noise, and confined spaces.
• Compliance with applicable company and client safety requirements, including annual drug testing requirements.

Pay Range:
The expected salary range for this position is $100,000 – $160,000. Compensation will be based on experience, qualifications, and location. Leveling may be adjusted based on candidate experience.

Application Deadline:
This position will remain open until filled. Applications will be reviewed on a continuous basis. To ensure full consideration, applicants are encouraged to submit their applications at the earliest opportunity.

Export Control Notice:
Certain positions at SI may require access to information and technology which is 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 SI limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List: .

About Us:
SIA is an engineering consulting firm serving various industries including Nuclear Power, Energy Services, Pipeline Integrity, and Critical Infrastructure. Join a team of internationally recognized experts in a culture based on knowledge, excellence, and respect for one another. Our employees are members of a distinct community of internationally respected professionals committed to quality, engineering innovation and a shared goal of building a safer world.

Why Work at SIA?
SIA offers a competitive salary and performance-based bonus program. Our retirement benefits include a Traditional 401k, Roth 401k, and an employer match. To help employees maintain a work-life balance, SIA also offers various paid time off including vacation, floating holidays, sick time, and parental leave.

Our employees also enjoy a comprehensive benefits program that includes the following:

• Medical, dental, and vision insurance
• Life Insurance and AD&D
• Short-term and long-term disability
• Health Savings Account with employer contribution
• Flexible Spending Account for health care and dependent care
• ID theft protection and credit monitoring

Structural Integrity Associates, Inc. is an equal opportunity employer.



SIA does not welcome third-party recruiters, employment agencies, headhunters, etc. Please do not reach out to SIA employees requesting a call, sit down, meeting, or email response.

Candidate information may be verified during the hiring process. Inaccurate, deceptive, or mass-generated applications may be disqualified from consideration.

Originally posted on Himalayas