Senior Mechanical Engineer - Thermo/Fluid Systems

About the role

The position requires deep experience in turbomachinery thermo-fluids engineering and familiarity with major OEM steam and gas turbine platforms. The successful candidate will apply advanced analytical methods, including Digital Twin development, to support performance evaluation, failure mode assessment, remaining life estimation, 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

• Perform advanced thermal and structural stress analyses of turbomachinery components, gas and steam turbine rotors, and auxiliary equipment using classical methods and finite element analysis tools such as ANSYS and Abaqus
• Develop and apply system and component level thermo-fluid and performance models for steam and gas turbines, including Digital Twin models (AxStream) for predictive analytics and lifecycle management
• Conduct ASME Code evaluations and ensure compliance with applicable industry standards and best practices
• Utilize thermo-fluid simulation tools (e.g., AxStream, ANSYS Fluent, STAR-CCM+) to evaluate flow behavior, operating conditions, performance characteristics, and generate boundary conditions for subsequent Thermo/Structural analysis and remaining life assessment
• Support nondestructive examinations and condition assessments, including metallurgical replication, hardness testing, ultrasonic inspection, and related techniques
• Provide technical input for failure investigations, root cause evaluations, and remaining life assessments
• Prepare clear, well-structured technical reports and client-facing presentations summarizing analyses, findings, and engineering recommendations
• Contribute to internal research and development initiatives focused on automation, AI-enabled methodologies, and continuous improvement of analysis techniques
• Support project managers in the execution of complex, multi-disciplinary engineering projects
• Lead or independently manage technical tasks and small-to-moderate scale projects as appropriate
• Ensure technical quality through peer review, documentation, and adherence to internal standards
• Maintain financial responsibility and comply with company guidelines related to project execution, expenses, and scheduling
• Approximately 25% travel annually, primarily associated with power plant outage seasons (spring and fall), field inspections, and reverse engineering activities at client or SIA facilities
• Occasional field work in operating power plant environments, which may include exposure to heat, noise, and confined space
• Ability to comply with annual respirator fit testing and drug-free workplace requirements

Qualifications

• Bachelor or Master degree in Mechanical Engineering or a related discipline
• 7–10 years of progressive experience in turbomachinery engineering, including steam and gas turbine design, analysis, or field engineering
• Proficiency in finite element analysis (FEA) tools (e.g., ANSYS, Abaqus) and thermo-fluid simulation software
• Strong understanding of turbomachinery operation, thermodynamics, fluid mechanics, fracture mechanics, fatigue, and finite element methods
• Advanced computer skills, including Microsoft Excel; experience with Mathcad, SQL, and scripting (VBA or similar) is a plus
• Excellent analytical, problem-solving, and written and verbal communication skills
• Professional Engineer (PE) license preferred or willingness to pursue licensure

Benefits

• Competitive salary and performance-based bonus program
• Traditional 401k, Roth 401k, and employer match
• Variety of paid time off including vacation, floating holidays, sick time, and parental leave
• Comprehensive benefits program including 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

Pay

The expected salary range for this role is $113,670 - $153,800 in San Jose, CA; $96,930 – $130,100 in Denver, CO. Exact pay will be commensurate with experience and location.

Schedule

Approximately 25% travel annually, primarily associated with power plant outage seasons (spring and fall), field inspections, and reverse engineering activities at client or SIA facilities.

Skills

• Thermal and structural stress analyses
• Turbomachinery engineering
• Finite element analysis (FEA) tools (e.g., ANSYS, Abaqus)
• Thermo-fluid simulation software
• ASME Code evaluations
• Nondestructive examinations and condition assessments
• Failure investigations
• Technical report preparation
• Internal research and development initiatives
• Project management
• Technical task and project management
• Financial responsibility and compliance with company guidelines
• Field work in operating power plant environments