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.

The position requires deep experience in turbo machinery thermo-fluids engineering and familiarity with major OEM steam and gas turbine platforms. The successful candidate will apply advanced analytical methods, including Digital Twin development, to support performance evaluation, failure mode assessment, remaining life estimation, and inspection planning. The role involves close collaboration with project managers, senior technical staff, and multidisciplinary teams, along with periodic travel to power generation facilities for field support and data collection.

• 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, 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

• 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…