Consultant, Mechanical Turbomachinery Engineer

Structural Integrity Associates, Inc. (SIA) is seeking an experienced Consultant specializing in turbo machinery 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.

• Perform advanced finite element thermal and structural stress analyses of turbo machinery components using engineering software, including ANSYS and Abaqus, as required.
• Develop detailed 2D and 3D models of turbo machinery 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.

• 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.

• Bachelor's degree in mechanical engineering or a related engineering discipline.
• Minimum of 10 years of relevant professional engineering experience, including significant experience in turbo machinery 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 turbo machinery components, including rotors and blades, using Solid Works 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,…