We are seeking a highly experienced and technically strong Senior Failure Analysis / RCA Engineer to lead advanced investigations into mechanical and performance-related failures of gas and steam turbines and associated rotating equipment. This role is critical to maintaining operational reliability, improving equipment life cycles, and driving organizational learning through structured root cause methodologies. The ideal candidate will bring deep knowledge of turbine behavior, mechanical failure mechanisms, and cross-functional investigative skills.
Lead high-impact investigations involving turbine components: rotors, blades, vanes, seals, diaphragms, bearings, couplings, casings, and valves.
Interpret failure signatures including fatigue, creep, corrosion, thermal distortion, erosion, FOD, HCF/LCF, and material degradation.
Direct on-site inspections, teardown evaluations, and lab testing coordination (NDT, SEM, metallurgical analysis).
Lead cross-functional RCA teams using structured methodologies:
Fault Tree Analysis, Apollo RCA, 5 Whys, FMEA, Fishbone Diagrams
Validate failure hypotheses with empirical data, material testing results, and operational trends.
Provide engineering judgment and risk analysis to differentiate between design, operational, and systemic causes.
Author high-quality investigation reports with evidence-based conclusions and risk mitigation strategies.
Present findings to executive leadership, OEMs, regulators, and plant operators.
Ensure traceability from failure to root cause to corrective action, with alignment to organizational asset strategies.
Influence long-term reliability programs, CAPEX investment planning, and design change decisions.
Recommend modifications in design, operation, or maintenance based on root cause data.
Contribute to asset strategies: RBI (Risk-Based Inspection), RCM (Reliability-Centered Maintenance), and lifecycle extension.
Oversee lab-based root cause evaluations: hardness testing, metallography, chemical analysis, replica testing.
Interpret lab data and correlate with field evidence and historical turbine performance.
Collaborate with OEMs (GE, Siemens, Mitsubishi, Alstom, etc.), third-party failure labs, and repair vendors.
Represent the organization in audits, insurance claims, and regulatory incident reviews.
Act as SME for internal teams on turbine failure prevention and analysis.
Bachelor’s degree in Mechanical Engineering, Metallurgical Engineering, Materials Science, or equivalent.
Master’s degree or industry certifications (e.g., API 579, Reliability Engineering, Six Sigma) are preferred.
Minimum 8 years of experience in failure analysis, mechanical integrity, or rotating equipment reliability.
Demonstrated expertise in analyzing gas and steam turbine failures in industrial or power generation environments.
Deep knowledge of turbine failure mechanisms, degradation modes, and forensic engineering.
Familiarity with API 687, API 579, ASME codes, OEM standards, and industry best practices.
Tools: RCPro, TapRooT, ReliaSoft, ANSYS (optional), SAP/Maximo, report automation tools.
Experience with CMMS, lab coordination, and turbomachinery asset management systems.
Strong technical leadership and problem-solving skills
Exceptional root cause investigation capability
Outstanding written and verbal communication
Strategic mindset with attention to detail
Ability to work cross-functionally with internal and external stakeholders