Sr. Mechanical Engineer

Location: Houston, Texas

Position status: Permanent

Exempt Status: Exempt

Job Summary:

CNPC USA is seeking a highly experienced Senior Mechanical Engineer to lead the mechanical design and development of MWD/LWD downhole tools, with an initial primary focus on high-speed mud pulse telemetry systems and new product developments (NPD). This position is a key technical role responsible for the mechanical architecture of the pulser and MWD tool assembly, including the pulser valve design, actuation mechanism, motor housing, flow path, pressure compensation, sealing, electronics packaging, and shock/vibration survivability in extreme drilling environments.

Working as part of a tightly integrated development team alongside the Electronics Engineer, Firmware Engineer, and MWD Development Lead, the Senior Mechanical Engineer will own the mechanical subsystem from concept and architecture through prototyping, qualification, field deployment, and commercialization. The ideal candidate brings a strong systems perspective and the ability to balance hydraulic, structural, thermal, and electronics-packaging requirements to deliver a reliable, high-data-rate pulse telemetry tool.

Key Responsibilities:

• Lead the mechanical architecture and design of MWD/LWD downhole tools, with an initial primary focus on high-speed mud pulser assemblies, from requirements definition through implementation and field release.
• Design the pulser mechanism to achieve target pulse rate, amplitude, and signal quality for high-speed telemetry.
• Collaborate closely with the Electronics Engineer, Firmware Engineer, and MWD Development Lead to define mechanical, electrical, and control interfaces and ensure end-to-end tool performance.
• Define mechanical packaging for downhole electronics and sensors, including chassis, mounting, shock/vibration isolation, and thermal paths within the tool collar.
• Design pressure barriers, sealing systems, and pressure-compensated or oil-filled sections for high-pressure, high-temperature downhole service.
• Perform structural, modal, fatigue, and tolerance-stack analyses (hand calculations and FEA) to ensure survivability under shock, vibration, and cyclic loading.
• Perform or direct flow/hydraulic analysis (CFD) of the pulser and flow path to optimize signal generation, minimize erosion, and manage pressure drop.
• Select materials and surface treatments for erosion, wear, corrosion, and high-temperature resistance in drilling-fluid environments.
• Create detailed 3D models, drawings, GD&T, and bills of materials; drive design-for-manufacturability and design-for-reliability.
• Build and test prototypes, including flow-loop, shaker/shock, pressure, and temperature testing; analyze results and iterate the design.
• Define and execute mechanical verification, qualification, reliability, and environmental test programs.
• Support manufacturing, assembly, vendor management, field deployment, and product sustainment, including investigation and root-cause analysis of mechanical failures.

Qualifications:

• Bachelor's degree in Mechanical Engineering or a related discipline; Master's degree or above is preferred.
• 8+ years of mechanical design and development experience, with demonstrated experience at a lead or principal level.
• Direct, hands-on experience developing high-speed mud pulser (MWD) telemetry tools and/or other MWD/LWD or downhole drilling products.
• Strong systems perspective, with a proven ability to integrate mechanical design with electronics, and overall tool requirements in a cross-functional team.
• Expertise in mechanical design of high-pressure, high-temperature assemblies, including sealing, pressure barriers, and rotating or actuated mechanisms.
• Proficiency with 3D CAD (e.g., SolidWorks, Creo, or NX), GD&T, and engineering drawing practices.
• Strong analytical capability in structural, modal, fatigue, and tolerance analysis, including FEA; familiarity with CFD/flow analysis is strongly preferred.
• Experience developing products for harsh environments, ideally including downhole, oilfield, aerospace, defense, or industrial ruggedized systems.
• Hands-on experience with prototyping and laboratory testing, including flow-loop, shock/vibration, pressure, and temperature testing.
• Strong troubleshooting and root-cause analysis capability for electromechanical systems.

Preferred Experience:

• Deep experience with mud-pulse telemetry pulsers (positive, negative, or continuous-wave/siren) and high-data-rate downhole telemetry.
• Experience with directional drilling tools, downhole sensors, drill collars, and threaded connections.
• Familiarity with electronics packaging, shock/vibration isolation, and thermal management for downhole electronics.
• Experience with materials selection for erosion, wear, and corrosion in drilling-fluid environments.
• Experience leading mechanical workstreams within an integrated MWD/LWD new product development program.
• Experience with manufacturing processes, vendor qualification, qualification testing, and product commercialization.
• Prior experience supporting both new product development and sustaining engineering for deployed tools.

Work Environment:

This job operates in a professional office environment. This role routinely uses standard office equipment, including computers, phones, photocopiers, filing cabinets, and fax machines.

Physical Demands:

The physical demands described here are representative of those that an employee must meet to successfully perform the essential job functions.

While performing the duties of this job, the employee is regularly required to talk or hear. This is a sedentary role; however, some filing, bending, and the ability to lift 20 lbs are required.

Travel:

This position requires some overnight international and domestic travel. Local travel between other CNPC USA locations and testing facilities is required.

Supervisory Responsibility:

This position has no direct supervisory responsibilities; however, it serves as a technical lead, mentor, and point of contact for less-experienced engineers.

Disclaimer: The job description is not intended to cover or contain a comprehensive listing of activities, duties, or responsibilities required of the employee. Other duties, responsibilities, and activities may change or be assigned at any time with or without notice.