Senior Mechanical Engineer - Thermo/Fluid Systems

SI Solutions, LLC; San Jose (CA); On-site; USD 114,000 - 154,000; Full time

Benefits offered by this job

Performance-based bonus

401k retirement plan

Paid time off

Job summary

Structural Integrity Associates, Inc. is seeking a Senior Mechanical Engineer specializing in thermo-fluid systems to lead advanced analysis for turbine generators within the Energy Services Group. The role focuses on thermomechanical assessments, lifecycle evaluation, and development of digital-twin analytics.

Travel about 25% yearly to field sites and outages; PE license preferred or pursuing licensure. Excellence in reporting and client communication is required, with leadership

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 tools (FEA) and thermo-fluid simulation software.

Responsibilities

• Perform advanced thermal and structural stress analyses of turbomachinery components using FEA tools.
• Develop thermo-fluid and performance models for steam and gas turbines, including Digital Twin models for predictive analytics.
• Conduct ASME Code evaluations and ensure compliance with industry standards.
• Prepare technical reports and client-facing presentations summarizing analyses and recommendations.
• Contribute to internal R&D initiatives on automation and AI-enabled methodologies.

Skills

Thermal analysis

Structural analysis

Technical leadership

Documentation

Communication

Education

Bachelors/Masters Mechanical Engineering

Tools

ANSYS

Abaqus

AxStream

STAR-CCM+

ANSYS Fluent

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 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.

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 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

Business

• 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

Project Management

• 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

Travel 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 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

Education and Experience

• 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

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.

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:

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.

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