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 turbomachinery 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.Responsibilities and Qualifications:Technical:Perform advanced thermal and structural stress analyses of turbomachinery components, gas and steam turbine rotors, and auxiliary equipment using classical methods and finite element analysis tools such as ANSYS and AbaqusDevelop 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 managementConduct ASME Code evaluations and ensure compliance with applicable industry standards and best practicesUtilize 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 techniquesProvide technical input for failure investigations, root cause evaluations, and remaining life assessmentsPrepare clear, well-structured technical reports and client-facing presentations summarizing analyses, findings, and engineering recommendationsContribute to internal research and development initiatives focused on automation, AI-enabled methodologies, and continuous improvement of analysis techniquesBusiness:Support project managers in the execution of complex, multi-disciplinary engineering projectsLead or independently manage technical tasks and small-to-moderate scale projects as appropriateEnsure technical quality through peer review, documentation, and adherence to internal standardsMaintain financial responsibility and comply with company guidelines related to project execution, expenses, and schedulingProject Management:Support project managers in the execution of complex, multi-disciplinary engineering projectsLead or independently manage technical tasks and small-to-moderate scale projects as appropriateEnsure technical quality through peer review, documentation, and adherence to internal standardsMaintain financial responsibility and comply with company guidelines related to project execution, expenses, and schedulingTravel and Working Conditions:Approximately 25% travel annually, primarily associated with power plant outage seasons (spring and fall), field inspections, and reverse engineering activities at client or SIA facilitiesOccasional field work in operating power plant environments, which may include exposure to heat, noise, and confined spaceAbility to comply with annual respirator fit testing and drug-free workplace requirementsEducation and Experience:Bachelor or Master degree in Mechanical Engineering or a related discipline7–10 years of progressive experience in turbomachinery engineering, including steam and gas turbine design, analysis, or field engineeringProficiency in finite element analysis (FEA) tools (e.g., ANSYS, Abaqus) and thermo-fluid simulation softwareStrong understanding of turbomachinery operation, thermodynamics, fluid mechanics, fracture mechanics, fatigue, and finite element methodsAdvanced computer skills, including Microsoft Excel; experience with Mathcad, SQL, and scripting (VBA or similar) is a plusExcellent analytical, problem-solving, and written and verbal communication skillsProfessional Engineer (PE) license preferred or willingness to pursue licensureThis position could be re-coded for a suitable candidate with more experience and subject matter expertisePay Range: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.Structural Integrity Associates, Inc. (SIA) does not welcome third-party recruiters, employment agencies, or headhunters. Please do not contact SIA employees directly to request meetings, calls, or email responses.Export Control Notice:Certain positions at SIA 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 SIA limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List: https://www.ecfr.gov/current/title-10/chapter-III/part-810/appendix-Appendix A to Part 810.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 insuranceLife Insurance and AD&DShort-term and long-term disabilityHealth Savings Account with employer contributionFlexible Spending Account for health care and dependent careID theft protection and credit monitoringStructural Integrity Associates, Inc. is an equal opportunity employer.www.structint.com SIA does not welcome third-party recruiters, employment agencies, headhunters, etc. Please do not reach out toSIA employees requesting a call, sit down, meeting, or email response.Powered by JazzHRE3TziDcxmo

Salary : $113,670 - $153,800