Senior Turbomachinery Engineer, Structural Analysis & Design

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.
Structural Integrity Associates, Inc. (SIA) does not welcome third-party recruiters, employment agencies, or headhunters. Please do not contact SIA employees directly to request meetings, calls, or email responses.
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.
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