Electrical Design Engineer Power Transformers

Core Design, Winding Design, Impedance, Losses & Electrical Performance

Department: Engineering Power Transformer Design

Position: Electrical Design Engineer Power Transformers

Reports To: Senior Engineering Manager Power Transformer Design

Technical Guidance: Senior Electrical Design Expert EHV

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 technically competent and motivated Electrical Design Engineer Power Transformers to support the electrical and electromagnetic design of oil-immersed power transformers for utility, industrial, and power generation applications.

The successful candidate will be responsible for performing detailed electrical design calculations, developing core and winding designs, calculating transformer losses and impedance, preparing electrical design documentation, and supporting manufacturing and factory testing.

The position requires a strong understanding of transformer design principles, electrical engineering fundamentals, manufacturing processes, and applicable IEEE/ANSI standards.

The Electrical Design Engineer will work closely with senior electrical, dielectric, thermal, and mechanical engineering specialists to develop reliable, cost-effective, and manufacturable transformer designs.

The primary objective is to deliver accurate electrical designs that meet customer specifications, guaranteed performance requirements, manufacturing capabilities, and project delivery schedules.

2. Key Responsibilities

A. Transformer Core Design

- Perform transformer core sizing and magnetic circuit calculations.
- Calculate core cross-sectional area, flux density, volts per turn, and number of turns.
- Select electrical steel grades and evaluate core construction requirements.
- Calculate no-load losses and excitation current.
- Evaluate core saturation and overexcitation requirements.
- Prepare core design data and material specifications.
- Coordinate core design with manufacturing and mechanical engineering teams.
- Support core design optimization for losses, material utilization, and cost.

B. Transformer Winding Design

- Perform detailed electrical design of HV, LV, tertiary, and regulating windings.
- Determine winding turns, conductor sizes, current density, and winding dimensions.
- Develop winding arrangements using disc, helical, layer, and other suitable winding constructions.
- Calculate winding resistance and conductor losses.
- Evaluate parallel conductor arrangements and circulating-current effects.
- Prepare winding design data, conductor specifications, and winding schedules.
- Coordinate winding geometry with dielectric, thermal, and mechanical design requirements.
- Support optimization of copper consumption, winding dimensions, and manufacturing efficiency.

C. Impedance Calculations

- Calculate transformer leakage reactance and short-circuit impedance.
- Evaluate impedance for specified winding combinations and tap positions.




- Analyze the effects of winding geometry, radial spacing, and axial dimensions on impedance.
- Verify calculated impedance against customer guarantees and design tolerances.
- Support investigation of differences between calculated and measured impedance.
- Maintain impedance calculation records and design verification documentation.

D. Transformer Loss Calculations

- Calculate no-load losses, winding resistance losses, and load losses.
- Estimate winding eddy-current and circulating-current losses.
- Support stray-loss calculations in windings, leads, and structural components.
- Evaluate transformer efficiency and guaranteed loss requirements.
- Compare calculated losses with factory test results.
- Support design optimization to achieve performance and cost targets.

E. Short-Circuit Design Support

- Calculate rated currents and specified short-circuit current conditions.
- Support axial and radial electromagnetic force calculations.
- Provide winding geometry and electromagnetic design data to mechanical short-circuit specialists.
- Assist in evaluating winding mechanical withstand capability.
- Coordinate design changes required to improve short-circuit performance.
- Maintain short-circuit calculation and verification records.

F. Dielectric and Thermal Design Coordination

- Coordinate with dielectric specialists on winding insulation clearances and insulation structures.
- Provide winding arrangements and electrical data for impulse distribution and electric-field analysis.
- Support thermal engineers with winding losses, conductor dimensions, and cooling duct information.
- Incorporate approved dielectric and thermal design requirements into winding designs.
- Ensure consistency between electrical calculations, winding drawings, and manufacturing specifications.

G. Electrical Design Documentation

- Prepare detailed electrical design calculation sheets.
- Develop core and winding design specifications.
- Prepare winding data sheets, conductor schedules, and electrical bills of materials.
- Review winding drawings and electrical design documents.
- Maintain design calculation records and revision history.
- Support engineering change notices and design modifications.
- Ensure timely release of approved engineering documentation to manufacturing.

H. Manufacturing and Factory Testing Support

- Provide technical support during core manufacturing and winding production.
- Resolve electrical design-related manufacturing queries.
- Review winding dimensional deviations and evaluate their impact on performance.
- Support factory testing of transformer losses, impedance, excitation current, and winding resistance.
- Compare measured test results with design predictions.




- Assist in root-cause investigations of electrical performance deviations.
- Implement corrective actions under the guidance of senior engineering specialists.

I. Design Optimization and Continuous Improvement

- Support optimization of core steel and conductor material consumption.
- Evaluate alternative winding arrangements and conductor sizes.
- Improve accuracy and efficiency of electrical design calculations.
- Participate in standardization of transformer design methodologies.
- Support development of engineering calculation tools and design databases.
- Contribute to lessons-learned reviews and continuous improvement initiatives.

3. Required Qualifications

Education

- Bachelor's degree in Electrical Engineering.
- Master's degree in Electrical Engineering or Power Engineering is preferred.

Professional Experience

- Minimum 37 years of electrical design experience, preferably in oil-immersed power transformers.
- Experience with power transformer core and winding design is strongly preferred.
- Familiarity with transformer impedance, loss, and winding calculations.
- Experience working with transformer manufacturing drawings and design documentation.
- Exposure to factory electrical testing and engineering problem-solving.
- Experience with transformers in the 33 kV, 69 kV, 115 kV, 138 kV, or 230 kV classes is advantageous.

Candidates with strong electrical engineering fundamentals and relevant transformer design experience at lower voltage classes may also be considered. 4. Essential Technical Competencies

Transformer Electrical Design

- Core sizing and magnetic circuit calculations.
- Winding design and conductor selection.
- Current density and winding resistance calculations.
- Leakage reactance and impedance calculations.
- No-load and load-loss calculations.

Engineering Fundamentals

- Electromagnetic theory.
- Electrical machines.
- Magnetic circuits.
- Electrical insulation fundamentals.
- Transformer equivalent circuits.
- Three-phase electrical systems.

Design Software

- Transformer electrical design calculation software.
- Microsoft Excel and engineering calculation tools.
- MATLAB or Python is advantageous.
- Familiarity with AutoCAD or equivalent drawing software.
- Experience with engineering BOM and ERP systems is preferred.

Standards

- Familiarity with IEEE C57.12.00.
- Familiarity with IEEE C57.12.90.
- Familiarity with IEEE C57.12.10.
- Basic understanding of IEC 60076 standards.
- Ability to interpret customer transformer specifications.

5. Professional Competencies

- Strong analytical and engineering calculation skills.
- Attention to detail and technical accuracy.
- Ability to understand and apply engineering design principles.
- Valuable problem-solving and troubleshooting capabilities.
- Ability to work with multidisciplinary engineering teams.
- Willingness to learn advanced transformer design methodologies.
- Strong documentation and communication skills.
- Ability to manage multiple design assignments and meet project deadlines.
- Commitment to product quality, reliability, and continuous improvement.

📌 Electrical Design Engineer - Power Transformer (Delhi)
🏢 Virginia Transformer
📍 Delhi