Senior Turbomachinery Engineer, Structural Analysis & Design

SI Solutions, LLC•,

4d•$110,000 - $160,000•Hybrid

About The Position

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.

Requirements

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

Nice To Haves

Professional Engineer (PE) license
Experience with AxStream, CFD tools, or automation tools (Python, VBA, SQL)

Responsibilities

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
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
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