Consultant, Mechanical Turbomachinery Engineer

Structural Integrity Associates, Inc. (SIA) is hiring an experienced Consultant specializing in turbomachinery structural design and analysis. The role leads thermal and structural analyses, digital twin modeling, reverse engineering, equipment condition assessments, and remaining-life evaluations for rotating equipment, while providing technical leadership and client support.

Responsibilities:

• Perform advanced finite element thermal and structural stress analyses of turbomachinery components using engineering software, including ANSYS and Abaqus, as required
• Develop detailed 2D and 3D models of turbomachinery components and assemblies, including gas and steam turbine rotors and blades, to support engineering analysis and reverse engineering activities
• Conduct applicable ASME Code evaluations and ensure engineering analyses comply with relevant industry standards and design criteria
• Develop, maintain, and utilize analytical digital twin models of gas and steam turbines to support equipment performance evaluations, predictive analytics, and lifecycle management
• Utilize thermodynamic and fluid dynamics software, including AxStream, Fluent, and STAR-CCM+, as required, to support performance and flow analyses
• Integrate thermal and fluid simulation results, including boundary conditions developed using AxStream, into structural FEA models
• Evaluate equipment operating conditions, including temperature distributions, stresses, strains, and material behavior, to assess potential failure mechanisms and remaining service life
• Support the evaluation of nondestructive examination (NDE) results and equipment condition assessments, including metallurgical replication, hardness testing, and ultrasonic inspection techniques
• Prepare and present detailed technical reports, engineering calculations, and recommendations to clients and internal stakeholders
• Contribute to internal research and development initiatives focused on process automation, artificial intelligence applications, and improvements in engineering analysis methods and accuracy
• Provide technical leadership, guidance, and mentorship to junior engineers and analysts to support professional development and knowledge transfer
• Serve as a primary technical point of contact for clients, ensuring effective communication of project objectives, deliverables, and engineering recommendations
• Lead technical discussions, client meetings, and presentations to communicate project findings and support long-term client relationships
• Collaborate with multidisciplinary teams and other SIA business units to develop engineering solutions that align with client needs and operational requirements
• Provide technical oversight and support throughout project execution to ensure quality, accuracy, and timely delivery of engineering services

Requirements:

• Bachelor's degree in mechanical engineering or a related engineering discipline
• Minimum of 10 years of relevant professional engineering experience, including significant experience in turbomachinery structural design, analysis, or field service engineering support
• Demonstrated technical expertise in gas or steam turbine design, structural analysis, and equipment evaluation
• Proficiency in 2D and 3D modeling of turbomachinery components, including rotors and blades, using SolidWorks or comparable CAD software
• Proficiency in finite element analysis software, including ANSYS or Abaqus, and experience with thermodynamic or fluid simulation software, including AxStream
• Strong understanding of creep, fatigue, fracture mechanics, and finite element methods as they relate to equipment failure mechanisms and remaining life assessments
• Demonstrated ability to independently lead complex engineering analyses, interpret technical results, and develop practical engineering recommendations
• Advanced computer skills, including proficiency with Microsoft Excel and ability to automate/optimize processes via the use of AI tools
• Strong analytical, problem-solving, organizational, and communication skills
• Ability to provide technical leadership and collaborate effectively with clients, multidisciplinary engineering teams, and other technical professionals
• Previous experience within the power generation, aerospace, or energy industries
• Master's degree or Ph.D. in Mechanical Engineering or a related engineering discipline
• Experience working with original equipment manufacturers (OEMs) or independent service providers
• Familiarity with gas and steam turbine operations, maintenance, and inspection practices
• Experience with fitness-for-service evaluations, remaining life assessments, reverse engineering, and equipment condition assessments
• Experience with Microsoft Access, SQL, and programming or scripting languages such as Python or VBA
• Professional Engineer (PE) license or willingness to pursue professional licensure