Senior Electrical Design Expert – EHV Power Transformers

Company: Virginia Transformer Corp

Department: Electrical Engineering – Power Transformer Design

Location: On Site

Employment Type: Full time

Experience Required: 10 to 15+ Years (Preferred)

Product Range: Oil-Immersed Power Transformers up to 250 MVA, 230 kV Class

Job Function: Electrical Engineering

Job Summary

Virginia Transformer Corp. is seeking a highly experienced and technically accomplished Senior Electrical Design Expert – EHV Power Transformers with strong expertise in electromagnetic design, core sizing, winding configurations, impedance calculations, loss optimization, stray-loss analysis, and short-circuit withstand capability of large oil-immersed power transformers.

The successful candidate will be responsible for independently developing, reviewing, validating, and optimizing electrical designs for EHV power transformers, ensuring compliance with applicable IEEE/ANSI standards, customer specifications, performance guarantees, and manufacturing requirements.

The role requires extensive hands-on transformer design experience, advanced analytical capabilities, and close collaboration with US-based engineering, manufacturing, and testing teams.

Key Responsibilities

- Transformer Core Design & Electromagnetic Optimization

- Perform electromagnetic design and optimization of transformer cores for large EHV power transformers.
- Determine core sizing, core cross-sectional area, flux density, core configuration, and magnetic circuit parameters.
- Optimize core design to minimize no-load losses, excitation current, noise, and material consumption.
- Evaluate electrical steel characteristics, magnetic flux distribution, and core saturation.
- Review core design calculations, material selection, and performance requirements.
- Ensure compliance with customer specifications and applicable IEEE/ANSI standards.

2. Winding Design & Configuration
- Design and optimize HV, LV, tertiary, and regulating windings for large power transformers.
- Determine winding configurations, conductor sizing, current density, turns distribution, and winding geometry.
- Evaluate winding arrangements, including disc, helical, layer, and interleaved winding designs, as applicable.
- Optimize winding design for electrical performance, thermal limits, short-circuit withstand capability, and manufacturing feasibility.
- Analyze eddy-current losses, circulating-current effects, conductor transposition, and current distribution.
- Coordinate winding design with dielectric, mechanical, and thermal engineering requirements.

3. Impedance Calculations & Optimization
- Perform transformer leakage impedance calculations and design verification.
- Evaluate leakage reactance, resistance, and impedance variations associated with winding configurations.
- Optimize winding geometry to achieve specified impedance values and guaranteed tolerances.
- Analyze impedance requirements for multi-winding transformers, autotransformers, and special applications.
- Support investigations of impedance deviations identified during factory testing.

4. Transformer Loss Calculations & Optimization
- Calculate and optimize no-load losses, load losses,



stray losses, and total transformer losses.
- Evaluate conductor resistance, winding eddy-current losses, and circulating-current losses.
- Analyze the influence of core materials, winding geometry, and structural components on transformer efficiency.
- Optimize transformer design considering material costs, guaranteed losses, and total owning cost.
- Review transformer loss calculations and support factory test result validation.
- Identify opportunities for electrical design improvements and cost optimization.

5. Stray-Loss & Leakage Flux Analysis
- Perform leakage magnetic flux analysis for transformer windings and structural components.
- Evaluate stray losses in tank walls, core clamps, structural supports, leads, and metallic components.
- Identify potential localized overheating caused by leakage flux.
- Conduct electromagnetic field simulations using ANSYS Maxwell, COMSOL Multiphysics, or equivalent software.
- Recommend magnetic shielding and structural design improvements to reduce stray heating.
- Validate analytical calculations and simulation results against factory testing and established design criteria.

6. Short-Circuit Forces & Withstand Capability
- Perform electrical and electromagnetic calculations related to transformer short-circuit withstand capability.
- Calculate axial and radial winding forces under short-circuit conditions.
- Evaluate winding mechanical stresses, electromagnetic forces, and critical short-circuit design parameters.
- Coordinate with mechanical design teams on winding clamping, support systems, and structural integrity.
- Review thermal withstand capability during short-circuit conditions.
- Ensure compliance with applicable IEEE/ANSI short-circuit performance requirements.

7. Electrical Design Verification & Technical Analysis
- Independently review and validate transformer electrical design calculations.
- Evaluate electromagnetic performance, winding configurations, impedance, losses, and short-circuit requirements.
- Support root-cause investigations of design-related manufacturing issues, abnormal test results, and field failures.
- Review transformer electrical performance guarantees against customer specifications.
- Develop standardized engineering calculation methodologies and design verification procedures.
- Recommend improvements to enhance efficiency, reliability, manufacturability, and cost competitiveness.

8. Engineering Coordination & Technical Leadership
- Serve as a senior technical specialist for transformer electromagnetic and electrical design.
- Collaborate with dielectric, mechanical, thermal, manufacturing, quality, and testing teams.
- Provide technical support to US-based engineering and manufacturing operations.
- Participate in engineering design reviews, customer technical discussions,



and design validation activities.
- Guide electrical design engineers in complex electromagnetic calculations and transformer design optimization.
- Support engineering automation, design standardization, and continuous improvement initiatives.

Required Qualifications & Experience
- Bachelor's degree in Electrical Engineering (B.E./B.Tech).
- Master's degree in Electrical Engineering, Power Engineering, or a related discipline preferred.
- Extensive relevant experience in electrical and electromagnetic design of oil-immersed power transformers; 10 to 15+ years preferred.
- Demonstrated experience designing large power transformers rated 100 MVA and above.
- Experience with 115 kV, 138 kV, and 230 kV class transformers preferred.
- Strong hands-on experience in transformer core sizing, winding arrangements, impedance calculations, and loss optimization.
- Proven expertise in leakage flux analysis, stray-loss calculations, and short-circuit force analysis.
- Strong understanding of transformer electrical performance, thermal limitations, and manufacturing constraints.
- Experience supporting transformer factory testing and engineering problem resolution.
- Strong knowledge of IEEE/ANSI standards and North American utility requirements.
- Excellent analytical, technical problem-solving, communication, and cross-functional collaboration skills.

Essential Technical Competencies

- Transformer electromagnetic design and calculations.
- Core sizing, magnetic flux density, and no-load loss optimization.
- HV/LV winding design and conductor selection.
- Leakage impedance calculations and optimization.
- Load losses, stray losses, and total loss evaluation.
- Leakage flux and magnetic shielding analysis.
- Axial and radial short-circuit force calculations.
- Transformer thermal and electrical performance evaluation.
- Electromagnetic simulation and FEA.
- ANSYS Maxwell, COMSOL Multiphysics, or equivalent simulation tools.
- Engineering calculation tools, including Excel, MATLAB, Python, or equivalent.
- Knowledge of IEEE C57 transformer design and testing standards.

Preferred Qualifications

- Experience designing EHV power transformers rated 150–250 MVA.
- Experience with autotransformers, generator step-up transformers, and multi-winding transformers.
- Knowledge of transformer design requirements for North American utilities.
- Advanced experience in electromagnetic field simulation and design optimization.
- Expertise in resolving complex impedance, loss, stray heating, and short-circuit design problems.
- Experience in transformer design automation, engineering standardization, and cost optimization.
- Ability to independently evaluate complex electrical designs and provide technically sound recommendations.

Why Join Virginia Transformer?

Join a global engineering organization and contribute to the development of high-performance power transformers for the North American market.

Collaborate with experienced engineering professionals and work on technically challenging transformer design projects.

Interested candidates can apply directly through LinkedIn.

Company Website: https://www.vatransformer.com/

📌 Senior Electrical Design Expert – EHV Power Transformers (Vadodara)
🏢 Virginia Transformer
📍 Vadodara