Senior Mechanical Engineer - Thermo/Fluid Systems

Structural Integrity Associates; Denver (CO); On-site; USD 96,930 - 130,100; Full time

Job summary

Structural Integrity Associates is seeking a Senior Mechanical Engineer to join our Energy Services Group in Denver, CO. This position involves leading advanced engineering analyses, conducting evaluations, and providing technical guidance on steam and gas turbine systems.

The ideal candidate will have a Bachelor or Master’s degree in Mechanical Engineering, and 7–10 years of experience. Skills in finite element analysis and thermo-fluid systems are essential. We offer a competitive salary and opportunities for professional growth.

Qualifications

• 7–10 years of progressive experience in turbomachinery engineering.
• Proficiency in FEA tools and thermo-fluid simulation software.
• Professional Engineer (PE) license preferred or willingness to pursue licensure.

Responsibilities

• Perform advanced thermal and structural stress analyses of turbomachinery components.
• Develop thermo-fluid and performance models for steam and gas turbines.
• Prepare clear technical reports and client presentations.

Skills

Finite element analysis (FEA)

Thermo-fluid simulation

Turbomachinery operation

Analytical skills

Problem-solving

Communication skills

Education

Bachelor or Master degree in Mechanical Engineering

Tools

ANSYS

Abaqus

AxStream

Job description

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 senior individual contributor role provides technical leadership in advanced engineering analysis, condition assessment, reverse engineering, and lifecycle evaluation of steam and gas turbine systems and components.

Responsibilities

• 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 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.

Qualifications

• Bachelor or Master degree in Mechanical Engineering or a related discipline.
• 7–10 years of progressive experience in turbomachinery 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 turbomachinery 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.

Travel & 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 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.

Pay 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.

Equal Opportunity Employment

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