Consultant, Mechanical Turbomachinery Engineer

SI Solutions, LLC • ,

3d • $100,000 - $160,000

About The Position

Structural Integrity Associates, Inc. (SIA) is seeking an experienced consultant specializing in turbomachinery structural design and analysis, with a strong background in gas or steam turbines. The role provides advanced technical expertise in thermal and structural analysis and leads engineering projects involving rotating equipment, reverse engineering, fitness-for-service evaluations, and remaining life assessments. The consultant develops analytical digital twin models using computer-aided design (CAD) and finite element analysis (FEA) tools to evaluate equipment under transient and steady-state operating conditions and assess failure mechanisms, remaining service life, and appropriate inspection intervals.

The position collaborates with clients, multidisciplinary engineering teams, and senior technical personnel on equipment condition assessments, reverse engineering, and lifecycle evaluations of rotating and stationary components. It includes technical leadership and mentorship, client-facing project leadership, and oversight of engineering work to support quality, accuracy, and timely delivery.

Travel is less than 10% annually, primarily for occasional visits to power generation facilities during scheduled outage seasons, client sites, or maintenance, repair, and overhaul facilities. Occasional fieldwork may involve elevated temperatures, noise, and confined spaces. Employees must comply with applicable company and client safety requirements, including annual drug testing requirements.

Requirements

• Bachelor’s degree in mechanical engineering or a related engineering discipline.
• At least 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.
• Ability to independently lead complex engineering analyses, interpret technical results, and develop practical engineering recommendations.
• Advanced computer skills, including Microsoft Excel proficiency and ability to automate or optimize processes using 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.

Nice To Haves

• Master’s degree or Ph.D. in mechanical engineering or a related engineering discipline.
• Previous experience in the power generation, aerospace, or energy industries.
• 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.

Responsibilities

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

Benefits

• Competitive salary and performance-based bonus program.
• Traditional 401(k), Roth 401(k), and employer match.
• Paid time off, including vacation, floating holidays, sick time, and parental leave.
• 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.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior