Senior Turbomachinery Engineer, Structural Analysis & Design

SI Solutions, Inc.; Northern (KY); Hybrid; USD 110,000 - 160,000; Full time

Benefits offered by this job

Bonus program

Retirement benefits

PTO & holidays

Insurance package

Job summary

Structural Integrity Associates (SIA) is seeking a Senior Turbomachinery Engineer to lead advanced analysis and lifecycle evaluations for steam and gas turbine systems. You will apply FEA, Digital Twin development, and ASME/API standards to support remaining life assessments and uprates, collaborating with multidisciplinary teams.

The role requires deep turbomachinery expertise, CAD modeling, and strong communication skills.

Qualifications

• 10+ years in turbomachinery engineering (steam and/or gas turbines)
• Deep turbomachinery structural integrity expertise (rotors, blades)
• Proficiency in FEA tools (ANSYS Mechanical preferred)
• CAD modeling in SolidWorks or equivalent
• Knowledge of fatigue, creep, fracture mechanics, high-temperature material behavior
• Ability to apply ASME/API/OEM standards
• PE license preferred
• Willingness to travel ~10% for field support

Responsibilities

• Perform advanced thermo-mechanical and structural analyses of turbomachinery components using FEA tools
• Develop 2D/3D CAD models of turbine components
• Conduct steady-state and transient thermal analyses
• Evaluate damage mechanisms (LCF, HCF, TMF, creep, SCC, etc.)
• Perform fitness-for-service and remaining life assessments
• Develop Digital Twin models using operating data and inspection findings
• Interpret inspection and NDE data
• Provide input for failure investigations and risk assessments
• Prepare technical reports and client presentations
• Lead technical tasks and mentor junior engineers
• Support project management with schedule adherence and budgeting
• Travel to power generation facilities for field data collection

Skills

Leadership

Analytical thinking

Effective communication

Education

Bachelor’s or Master’s in Mechanical Engineering

PE license preferred

Tools

ANSYS Mechanical

SolidWorks

Python

VBA

SQL

AxStream

Job description

Structural Integrity Associates (SIA) is seeking a Senior Turbomachinery Engineer 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 structural analysis, condition assessment, reverse engineering, and lifecycle evaluation of steam and gas turbine systems and associated components.

The position requires deep expertise in turbomachinery structural integrity, including rotors and blades, across major OEM platforms. The successful candidate will apply advanced analytical methods, including finite element analysis (FEA) and Digital Twin development, to support remaining life assessment, fitness-for-service evaluations, failure analysis, 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 thermo-mechanical and structural analyses of turbomachinery components, including gas and steam turbine rotors, blades, casings, and auxiliary equipment using FEA tools such as ANSYS


• Develop detailed 2D and 3D CAD models (axisymmetric and solid) of turbine components using SolidWorks or equivalent


• Conduct steady-state and transient thermal analyses (startup, shutdown, cyclic duty, load-following)


• Evaluate damage mechanisms including LCF, HCF, TMF, creep, creep-fatigue interaction, fracture mechanics, SCC, fretting, and stress rupture


• Perform fitness-for-service (FFS) and remaining life assessment (RLA) evaluations to support continued operation, uprates, and life extension


• Apply ASME, API, OEM, and other applicable industry codes and standards


• Support reverse engineering activities, including field dimensional capture, material characterization, and redesign improvements


• Develop and apply Digital Twin models integrating operating data, inspection findings, and analytical results


• Interpret inspection and NDE data, including UT, MPI/PT, metallurgical replication, hardness testing, and borescope inspections


• Provide technical input for failure investigations, root cause analyses, and risk assessments


• Prepare clear, well-structured technical reports and client-facing presentations summarizing findings and recommendations

Business:

• Support project managers in the execution of complex, multi-disciplinary engineering projects


• Serve as a technical lead on projects and provide mentorship to junior engineers


• Contribute to business development efforts, including proposal support and technical scoping


• Maintain strong client relationships and serve as a trusted technical advisor

Project Management:

• Lead or independently manage technical tasks and small-to-moderate scale projects


• Ensure technical quality through peer review, documentation, and adherence to internal standards


• Maintain financial accountability and comply with company guidelines for project execution, scheduling, and expenses

Travel and Working Conditions:

• Approximately 10% travel annually, primarily aligned with outage seasons, inspections, or special client support activities


• Occasional field work in power plants, industrial sites, or manufacturing environments


• Ability to work safely in environments involving heat, noise, elevated platforms, and confined spaces


• Compliance with client safety, training, and testing requirements

Education and Experience:

• Bachelor’s or Master’s degree in Mechanical Engineering or related discipline


• 10+ years of progressive experience in turbomachinery engineering (steam and/or gas turbines)


• Strong proficiency in FEA tools (ANSYS Mechanical preferred)


• Strong experience with CAD modeling (SolidWorks or equivalent)


• Deep understanding of fatigue, creep, fracture mechanics, and high-temperature material behavior


• Excellent analytical, problem-solving, and communication skills


• Professional Engineer (PE) license preferred

Preferred / Nice to Have:

• Experience with AxStream, CFD tools, or automation tools (Python, VBA, SQL)

Pay Range:

The expected salary range for this position is $110,000 - $160,000. Compensation will be based on experience, qualifications, and location. Leveling may be adjusted based on candidate experience.

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 U.S. Department of Energy (DOE) in 10 CFR 810 and Nuclear Regulatory Commission (NRC) 10 CFR Part 110. Hiring decisions must comply with these regulations.

About Us:

SIA is an engineering consulting firm serving industries including Nuclear Power, Energy Services, Pipeline Integrity, and Critical Infrastructure. Join a team of internationally recognized experts committed to engineering excellence, innovation, and 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 employer match. We support work-life balance through paid time off including vacation, holidays, sick time, and parental leave.

Our comprehensive benefits package includes:

• Medical, dental, and vision insurance


• Life insurance and AD&D


• Short-term and long-term disability


• Health Savings Account with employer contribution


• Flexible Spending Accounts


• Identity 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.