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Thermo Operator Jobs (NOW HIRING)

Structural Integrity Associates, Inc

$113K - $153K/yr

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 ...

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What are the key skills and qualifications needed to thrive as a Thermo Operator, and why are they important?

To excel as a Thermo Operator, you need a solid understanding of industrial equipment operation, process control, and safety protocols, often supported by a high school diploma or technical certification. Experience with programmable logic controllers (PLCs), temperature monitoring systems, and preventive maintenance tools is typically required. Attention to detail, problem-solving abilities, and effective communication distinguish top performers in this role. These skills ensure safe, efficient, and consistent operation of thermal processing equipment, minimizing downtime and maintaining product quality.

What are some common challenges faced by a Thermo Operator, and how can they be managed effectively?

Thermo Operators often work in environments with high temperatures and complex machinery, which can present challenges such as maintaining equipment safety, minimizing downtime, and ensuring product quality. Effective communication with maintenance and quality control teams is essential to address technical issues promptly. Staying vigilant with regular equipment checks and adhering to safety protocols can help prevent accidents and keep production running smoothly. Continuous training and familiarization with new technologies also support long-term success in this role.

What are Thermo Operators?

Thermo Operators are professionals responsible for monitoring and controlling thermal or heat-based machinery and equipment, often in industrial settings such as manufacturing plants or power generation facilities. Their duties include overseeing the operation of boilers, heaters, furnaces, or other thermal systems to ensure safe and efficient performance. Thermo Operators must follow strict safety protocols, perform routine maintenance, and respond to system alarms or malfunctions. They often work as part of a team and may assist with troubleshooting and repairs to minimize downtime.

What is the difference between Thermo Operator vs Boiler Operator?

AspectThermo OperatorBoiler Operator
CertificationsTypically requires HVAC or thermal process certificationsRequires boiler operation licenses or certifications
Work EnvironmentIndustrial plants, manufacturing facilities, power plantsPower plants, manufacturing facilities, heating systems
Job ResponsibilitiesOperate and monitor thermal systems, maintain equipmentOperate and maintain boilers, ensure safety and efficiency

Both roles involve operating thermal equipment in industrial settings, but Thermo Operators focus on thermal systems and processes, while Boiler Operators specialize in boiler systems. The certifications and daily tasks overlap, making them closely related but distinct roles within thermal operations.

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Thermo Operator jobs near you
Infographic showing various Thermo Operator job openings in the United States as of May 2026, with employment types broken down into 2% Full Time, and 98% Part Time. Highlights an 87% Physical, 1% Hybrid, and 12% Remote job distribution.
Senior Mechanical Engineer - Thermo/Fluid Systems

Senior Mechanical Engineer - Thermo/Fluid Systems

SI Solutions, LLC

San Jose, CA • On-site

$113K - $153K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Posted 6 days ago

Job description

Structural Integrity Associates (SIA) is seeking a Senior Mechanical Engineer with expertise in thermo-fluid systems 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 engineering analysis, condition assessment, reverse engineering, and lifecycle evaluation of steam and gas turbine systems and associated components.
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 and Qualifications:
Technical:
  • 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
Business:
  • 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
Project Management:
  • 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
Travel and Working Conditions:
  • 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
Education and Experience:
  • 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
  • This position could be re-coded for a suitable candidate with more experience and subject matter expertise
Pay Range:
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.
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 US Department of Energy (DOE) in 10 CFR 810 and Nuclear Regulatory Commission (NRC) 10 CFR Part 110. Hiring decisions for such positions must comply with these regulations and may result in SIA limiting its consideration of foreign nationals who are citizens of countries that are not on the DOE’s Generally Authorized Destinations List: https://www.ecfr.gov/current/title-10/chapter-III/part-810/appendix-Appendix%20A%20to%20Part%20810.
About Us:
SIA is an engineering consulting firm serving various industries including Nuclear Power, Energy Services, Pipeline Integrity, and Critical Infrastructure. Join a team of internationally recognized experts in a culture based on knowledge, excellence, and respect for one another. Our employees are members of a distinct community of internationally respected professionals committed to quality, engineering innovation and a shared goal of 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 an employer match. To help employees maintain a work-life balance, SIA also offers various paid time off including vacation, floating holidays, sick time, and parental leave.
Our employees also enjoy a comprehensive benefits program that includes the following:
  • 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
Structural Integrity Associates, Inc. is an equal opportunity employer.
www.structint.com 
SIA does not welcome third-party recruiters, employment agencies, headhunters, etc. Please do not reach out to
SIA employees requesting a call, sit down, meeting, or email response.

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