Senior Mechanical Design Expert Power Transformers

Tank, Core Clamping, Internal & External Mechanical Assemblies

Department: Power Transformer Engineering Mechanical Design

Position: Senior Mechanical Design Expert / Lead Mechanical Design Engineer

Reports To: Senior Engineering Manager Power Transformer Design

Location: [Manufacturing Plant Location]

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

Employment Type: Full-Time

1. Position Summary

We are seeking a highly experienced and technically competent Senior Mechanical Design Expert to lead the mechanical design and engineering of large oil-immersed power transformers.

The successful candidate will be responsible for the complete mechanical design of transformer tanks, covers, core-and-coil clamping assemblies, internal support structures, external mechanical assemblies, and associated accessories.

The position requires extensive hands-on experience in transformer mechanical design, structural calculations, manufacturing processes, welding, material selection, and mechanical validation.

The candidate must possess the ability to independently develop, review, optimize, and approve mechanical designs for transformers rated up to 250 MVA, 230 kV class.

Working under the Senior Engineering Manager, the individual will provide technical leadership to mechanical designers and CAD engineers and coordinate closely with electrical design, manufacturing, quality, procurement, and testing departments.

The primary objective is to ensure mechanically robust, manufacturable, cost-effective, and reliable transformer designs that meet customer specifications and applicable IEEE/ANSI standards.

2. Key Responsibilities

A. Transformer Tank and Cover Design

Responsible for the complete mechanical design and engineering of transformer tanks and associated structures.

Key responsibilities include

- Design transformer tanks, covers, bases, sidewalls, stiffeners, and reinforcement structures.
- Perform structural calculations for tank wall thickness, cover thickness, stiffener sizing, and mechanical reinforcement.
- Design tanks to withstand specified vacuum, positive internal pressure, oil head, handling, and transportation loads.
- Evaluate tank deformation, stresses, and deflection under operating and test conditions.
- Design lifting lugs, jacking pads, pulling eyes, skid bases, and transportation support arrangements.
- Design tank flanges, gasket grooves, sealing arrangements, and bolted connections.
- Develop appropriate tank welding configurations and fabrication details.
- Design manholes, inspection openings, handholes, and maintenance access provisions.
- Evaluate tank structural integrity during vacuum filling, pressure testing, transportation, and installation.
- Optimize tank weight, structural steel consumption, welding requirements, and manufacturing cost.
- Support tank fabrication, dimensional inspection, leak testing, and structural validation.

B. Core-and-Coil Clamping Assembly Design Responsible for the mechanical design and structural integrity of transformer active-part clamping systems.

Key responsibilities include

- Design upper and lower core clamping frames, yoke beams, tie rods, clamping plates, and associated support structures.
- Develop mechanical arrangements for securing the core-and-coil assembly during manufacturing, transportation, and service.
- Design winding axial compression systems, pressure rings, and clamping arrangements in coordination with electrical design.
- Evaluate axial and radial winding forces during short-circuit conditions.
- Perform structural calculations for clamping members, tie rods, fasteners, and support structures.
- Ensure adequate winding compression and mechanical stability under short-circuit forces.
- Evaluate the effects of thermal expansion, insulation shrinkage, vibration, and long-term mechanical relaxation.
- Design core support arrangements, core-to-tank mounting structures, and active-part lifting arrangements.
- Coordinate mechanical designs with magnetic flux and stray-loss considerations to prevent excessive heating of structural components.
- Optimize clamping assembly weight, material utilization, assembly time, and manufacturing cost.

C. Internal Mechanical Assembly Design Responsible for the mechanical design of internal transformer components and support structures.

Key responsibilities include

- Design internal lead support structures, brackets, clamps,



and mechanical supports in coordination with the electrical insulation design team.
- Design support arrangements for high-voltage, low-voltage, neutral, and tap-changer leads.
- Ensure mechanical stability of internal connections under short-circuit, transportation, vibration, and thermal loading.
- Design mechanical supports for insulation barriers, cylinders, spacers, and other insulating structures.
- Develop mounting and support arrangements for tap changers, internal current transformers, and associated components.
- Design internal oil-flow arrangements and mechanical provisions supporting transformer cooling performance.
- Evaluate clearances between internal mechanical structures and energized components in coordination with electrical engineering.
- Ensure compatibility of internal materials with transformer oil, insulation systems, and operating temperatures.
- Develop practical assembly sequences for core-and-coil installation, lead connections, and tanking operations.
- Minimize the risk of mechanical movement, loose components, oil-flow obstruction, and insulation damage.

D. External Mechanical Assembly and Accessories Responsible for the mechanical design and integration of external transformer components.

Key responsibilities include

- Design mounting arrangements for bushings, turrets, and associated support structures.
- Design radiator banks, cooler mounting structures, oil piping, flanges, and supporting brackets.
- Develop conservator tank mounting arrangements and associated piping systems.
- Design supports for cooling fans, oil pumps, control cabinets, and auxiliary equipment.
- Develop mounting and connection arrangements for pressure relief devices, oil-level indicators, temperature indicators, and other accessories.
- Design drain valves, filter valves, sampling connections, air-release provisions, and oil-processing connections.
- Ensure accessibility for inspection, maintenance, testing, and replacement of external components.
- Coordinate external mechanical arrangements with transportation dimensional restrictions and site installation requirements.
- Review external assembly drawings to ensure compliance with customer specifications and approved general arrangement drawings.

E. Structural Analysis and Mechanical Calculations

- Perform engineering calculations for tank stresses, cover deflection, stiffener sizing, and structural integrity.
- Evaluate mechanical loads associated with lifting, jacking, transportation, and installation.
- Perform structural analysis of core clamping frames and winding support structures.
- Analyze bolted connections, welded joints, and structural members.
- Apply finite element analysis (FEA) for complex structural designs where necessary.
- Evaluate fatigue, vibration, and dynamic loading where applicable.
- Support seismic design and qualification when required by customer specifications.
- Validate mechanical calculations through design reviews, testing, and manufacturing feedback.
- Establish standardized calculation methods and design safety margins.

F. Mechanical Design for Manufacturing

- Ensure all mechanical designs are practical for fabrication, machining, welding, assembly, and inspection.
- Work closely with manufacturing teams to resolve tank fabrication, core assembly, and final assembly issues.
- Develop fabrication drawings with appropriate dimensions, tolerances, weld symbols, and material specifications.
- Apply Design for Manufacturing and Assembly (DFMA) principles.
- Optimize mechanical designs to reduce material consumption, welding time, fabrication complexity, and assembly labor.
- Evaluate fabrication capabilities and establish practical design tolerances.
- Support the qualification of new fabrication processes and mechanical component suppliers.
- Review and approve mechanical design deviations and manufacturing concessions within assigned authority.
- Participate in root-cause analysis of mechanical failures, oil leaks, excessive vibration, structural deformation, and assembly-related problems.

G.



Engineering Documentation and Design Control

- Prepare and review mechanical general arrangement drawings, fabrication drawings, assembly drawings, and detailed component drawings.
- Develop and maintain mechanical bills of materials.
- Establish standardized mechanical design practices, calculation sheets, and engineering checklists.
- Ensure effective revision control and engineering change management.
- Maintain complete design records and supporting calculations.
- Coordinate mechanical drawing releases with project and manufacturing schedules.
- Ensure technical consistency between electrical, mechanical, and manufacturing documentation.

H. Cross-Functional Technical Coordination

- Work closely with electrical design engineers to integrate electromagnetic, dielectric, thermal, and mechanical requirements.
- Coordinate with manufacturing engineering on fabrication and assembly methods.
- Support procurement in evaluating mechanical components, materials, and supplier drawings.
- Collaborate with quality and testing teams to resolve mechanical nonconformances.
- Participate in customer design reviews and technical clarification meetings.
- Provide technical guidance to mechanical designers, drafting engineers, and junior engineers.
- Report engineering progress, technical risks, and design challenges to the Senior Engineering Manager.

3. Required Qualifications

Education

- Bachelor's degree in Mechanical Engineering.
- Master's degree in Mechanical Engineering, Structural Engineering, or a related discipline is preferred.

Professional Experience

- Minimum 1215 years of mechanical design experience, preferably in oil-immersed power transformer manufacturing.
- At least 810 years of direct experience designing transformer tanks, core clamping structures, and mechanical assemblies.
- Demonstrated experience with power transformers rated 100 MVA and above.
- Experience with 115 kV, 138 kV, or 230 kV class transformers is strongly preferred.
- Proven ability to independently perform and verify mechanical design calculations.
- Experience supporting transformer fabrication, assembly, and factory testing.
- Previous experience providing technical leadership to mechanical design engineers and CAD designers.

4. Essential Technical Competencies The candidate must demonstrate strong technical proficiency in the following areas.

Transformer Tank Engineering

- Tank structural design and reinforcement.
- Vacuum and pressure load calculations.
- Tank deformation and deflection analysis.
- Welding design, flange design, and sealing systems.
- Lifting, jacking, and transportation engineering.

Core Clamping and Internal Structures

- Core-and-coil clamping frame design.
- Winding compression and short-circuit force considerations.
- Tie rod, beam, and structural support calculations.
- Internal support systems and active-part mounting arrangements.
- Mechanical and thermal expansion considerations.

Mechanical Analysis

- Strength of materials and structural mechanics.
- Static and agile load calculations.
- Finite element analysis.
- Welded and bolted joint design.
- Vibration and fatigue considerations.

Design Software

- Proficiency in 3D CAD software such as SolidWorks, Autodesk Inventor, Creo, or equivalent.
- Experience with AutoCAD or equivalent 2D drafting tools.
- Working knowledge of ANSYS Mechanical, Abaqus, or equivalent FEA software.
- Familiarity with engineering BOM, PDM, and ERP systems.

Standards and Manufacturing

- Knowledge of applicable IEEE C57 transformer standards.
- Familiarity with AWS welding requirements and relevant ASTM material specifications.
- Understanding of transformer tank fabrication, welding, machining, and assembly processes.
- Ability to interpret customer specifications and translate them into mechanical design requirements.

5. Leadership and Professional Competencies

- Strong hands-on engineering and problem-solving skills.
- Ability to independently evaluate and challenge mechanical design concepts.
- Strong understanding of manufacturing constraints and practical fabrication methods.
- Ability to mentor mechanical engineers and CAD designers.
- Excellent communication and cross-functional coordination skills.
- Strong attention to engineering detail, safety, reliability, and cost.
- Ability to prioritize multiple engineering projects and meet manufacturing deadlines.
- Willingness to work directly with production teams to resolve engineering issues.

📌 Senior Mechanical Design expert- Power Transformer (Delhi)
🏢 Virginia Transformer
📍 Delhi