Senior Mechanical Thermal-Fluids Engineer

Fermi Research Alliance, LLC; Batavia (IL); On-site; USD 111,400 - 146,600; Full time

Benefits offered by this job

Medical, Dental, Vision insurance

Paid time off

Retirement benefits

Onsite day care

Job summary

Fermilab seeks a Senior Mechanical Thermal‑Fluids Engineer to lead the Thermal‑Fluids Engineering Group and oversee LBNF RAW Water Systems. You will design, model, test, fabricate, and operate fluid-cooling piping systems for accelerator components, using ANSYS, NASTRAN, Siemens NX, and 3D printing to prototype and validate your designs.

You will lead a team of drafters and engineers, coordinate with vendors, and ensure safety and quality across projects that support future accelerators.

Qualifications

• Bachelor’s or Master’s in engineering from ABET-accredited program with relevant years of experience.
• Experience in fluid-thermal system design, analysis, and piping.
• Ability to create/read P&IDs, 3D models and 2D drawings; familiarity with welding/brazing is a plus.

Responsibilities

• Lead the Thermal-Fluids Engineering Group and serve as Level 4 Technical Manager for LBNF RAW Water Systems.
• Design, model, test, and operate fluid-cooling piping systems for accelerator components.
• Perform piping flow and heat-transfer analyses; coordinate with vendors and collaborators.
• Develop and review mechanical drawings and specifications; manage drafter/tech team.
• Ensure environmental, health, and safety compliance in all activities.

Skills

Fluid mechanics

Thermodynamics

Heat transfer

Piping network calculations

Engineering mechanics

Welding/Brazing

CAD software

3D modeling

2D drawings

ASME/AISC codes

FEA / FEM

Communication

Education

ABET-accredited engineering degree

Tools

ANSYS Workbench

ANSYS Fluent

ANSYS CFX

NASTRAN

Siemens NX

3D printing

AFT Fathom

AutoCAD Plant

Job description

The expected hiring range for this position is: $111,400.00 - $146,600.00. Please note that the pay range information is a general guideline only. The pay offered to a selected candidate will be determined based on factors such as the scope and responsibilities of the position, qualifications of the selected candidate, business considerations, internal equity, and external market pay for comparable jobs.

About the Role

Fermilab is seeking a Senior Mechanical Thermal‑Fluids Engineer to lead the Thermal‑Fluids Engineering Group. The lead is a collaborator by nature and seeks out the latest technology and tools to design, fabricate, test, install and operate components and systems for our particle accelerators. We use the latest technology such as ANSYS, NASTRAN, Siemens NX, and additive manufacturing (3D printing) to model, simulate, prototype, and test our designs. We work with vendors who stretch their technical abilities to fabricate the next generation of components and systems. We expand our engineering skills and, sometimes, write the textbooks to operate the existing accelerators. We work with collaborators throughout the lab and the world to plan future accelerators for projects such as the Long Baseline Neutrino Facility (LBNF) and Proton Improvement Plan II (PIP‑II).

Day‑to‑Day Responsibilities

• Serve as the Thermal‑Fluids Engineering Group leader.
• Serve as the Level 4 Technical Manager for the LBNF RAW Water Systems.
• Utilize fundamental mechanical engineering concepts and principles to complete assignments and develop familiarity with the laboratory’s method of project engineering, from the design stage through review, procurement, fabrication, installation, test, and operation.
• Be involved in the mechanical design, analysis, specification, and construction of fluid cooling piping systems that support the operation of the accelerator complex, including the temperature control of beamline components (such as magnets, collimators, RF cavities, beam instrumentation, high‑powered targets, kickers, and associated beam components).
• Participate in and lead efforts involving general mechanical‑system design, thermal‑fluid system design, piping system fluid flow analysis, and heat transfer analysis.
• Learn the operations of existing accelerator fluids systems and provide operations engineering support by troubleshooting system issues and designing upgrades to existing systems to improve their reliability.
• Participate in the design of compressible and incompressible thermal fluids systems to support the accelerator.
• Fabricate systems using different types of welding, brazing, bonding, and soldering techniques with materials such as aluminum, stainless steel, copper, brass, PVC, CPVC, PVDF, etc.
• Work in a team environment.
• Be responsible for directing the activities of drafters, designers, technicians, and skilled trades on their projects.
• Communicate with outside vendors, contractors, and fabricators through written specifications and engineering drawings.
• Direct the activities of co‑op engineering students and interns on their projects.
• Abide by and be responsible for performing all duties in accordance with all environmental, health and safety regulations and practices pertinent to this position.

Skills and Attributes for Success

• Bachelor’s in an applicable Engineering discipline from an ABET accredited institution with 8+ years of engineering experience, or a Master’s in an applicable Engineering discipline from an ABET accredited institution with 6+ years of engineering experience.

Applicable Knowledge, Skills and Abilities Required

• Demonstrated ability to communicate expectations clearly using verbal and written practices with customers / stakeholders and with team members.
• Demonstrated ability to work effectively under the requirements of schedules and shifting priorities.
• Demonstrated ability to perform fluid mechanics, thermodynamics, heat transfer, piping network calculations and engineering mechanics calculations including statics, stress, strain, and deflection.
• Demonstrated knowledge of machine shop practices and techniques for fabricating complex and intricate hardware.
• Knowledge of welding and brazing practices (e.g., TIG, MIG and torch brazing) as related to manufacturing and fabrication of piping is desirable.
• Must have strong computing skills including preparing and documenting engineering calculations, creating 3‑D models and 2‑D drawings using CAD software, FEA analyses, data presentation, and project management activities (cost estimates, schedules).
• Skills in AFT Fathom, AFT Arrow, ANSYS Workbench, ANSYS Fluent, or ANSYS CFX are desirable.
• Demonstrated ability to create and read mechanical drawings, including piping and instrumentation diagrams (P&ID) and process piping flow schematics.
• Familiarity of CAD software toward the creation of piping fluid flow network systems is a plus.
• Skills in AutoCAD Plant are desirable.
• Use of geometric dimensioning and tolerancing on drawings is desirable.
• Demonstrated ability to creatively solve engineering problems and troubleshoot operational issues.
• Knowledge of materials, metallurgy and radiation damage of materials is desirable.
• Knowledge of code standards such as ASME, AISC and ANSI/ASME pressure vessel and piping codes is desirable.
• Basic understanding of electrical engineering concepts such as current, voltages, resistance, and frequencies.

Physical Activity and Work Conditions

• HUMAN FACTORS: Heights, working in underground enclosures, mental concentration, sitting, standing, tight work schedule, visually demanding.

Work Arrangement

Please note that the described work arrangement is subject to change based on business needs and is not guaranteed to be final.

• ON SITE: This is an onsite role, and the candidate must be able to work from our Batavia office.

Benefits and Perks

Fermilab offers a competitive and comprehensive benefits program, including:

• Medical, Dental, Vision and Flexible Spending Accounts
• Paid time off
• Life insurance
• Short and Long‑term disability insurance
• Retirement benefits
• Onsite day care

Why Fermilab

Fermilab is America’s premier laboratory for particle physics and accelerator research, funded by the U.S. Department of Energy. We support discovery science experiments in Illinois and locations around the world, including deep underground mines in South Dakota and Canada, mountain tops in Arizona and Chile, CERN in Europe and the South Pole.

Pre‑Employment Screening

• Drug‑Free Workplace & Pre‑Employment Screening: Fermilab is dedicated to fostering a safe, productive and drug‑free environment. An offer of employment is contingent upon the successful completion of a background check and drug screening.
• HSPD‑12: In accordance with Homeland Security Presidential Directive 12 (HSPD‑12) new employees are required to obtain and maintain a HSPD‑12 Personal Identity Verification (PIV) Credential. To obtain this credential, new employees must successfully complete and pass a federal background check investigation. This investigation includes a declaration of illegal drug activities, including use, supply, possession, or manufacture. This includes marijuana and cannabis derivatives, which are still considered illegal under federal law, regardless of state laws. Failure to obtain or maintain such government access authorization could result in the withdrawal of a job offer or future termination of employment.
• Foreign Government Sponsored Activities: Fermilab employees, and certain guest researchers and contractors, are subject to particular restrictions related to participation in Foreign Government Sponsored or Affiliated Activities, as defined and detailed in United States Department of Energy Order 486.1A. Such individuals will be asked to disclose any participation for review by Fermilab’s Office of General Counsel.
• REAL‑ID Requirement for access to Fermilab Campus: Fermilab requires all members of the public to produce a REAL‑ID, or equivalent, to access the Fermilab Campus for interviews or career events. A list of acceptable forms of ID can be found here: https://get-connected.fnal.gov/wp-content/uploads/2021/09/REALID-Documents.pdf. If a candidate is selected for an interview but does not possess any of the equivalent documents, we may schedule a virtual interview.
• Equal Opportunity Statement: Fermilab is an equal opportunity employer. We evaluate qualified applicants without regard to race, color, religion, sex, age, national origin, disability, veteran status, genetic information, and other legally protected categories.