Senior Electrical Design Expert – EHV Power Transformers

Virginia Transformer Corp; Vadodara; On-site; INR 1,800,000 - 3,500,000; Full time

Job summary

Virginia Transformer Corp. seeks a highly experienced Senior Electrical Design Expert – EHV Power Transformers with deep electromagnetic design, core sizing, winding configurations, impedance, and loss optimization expertise.

You will independently develop and validate electrical designs for oil-immersed EHV transformers, ensuring IEEE/ANSI standards compliance and alignment with customer specs and manufacturing needs.

Qualifications

• Bachelor's degree in Electrical Engineering; Master’s preferred.
• 10+ years in electrical design for large transformers.
• Experience with 100 MVA class transformers and 115/138/230 kV class performance.

Responsibilities

• Lead core electromagnetic design and optimization for EHV transformers.
• Design HV/LV windings, winding configurations, and conductor sizing.
• Perform impedance calculations and optimize losses and thermal performance.
• Analyze leakage flux, stray losses, and short-circuit forces with simulations.
• Coordinate with mechanics, dielectric, and manufacturing teams; support testing.
• Ensure compliance with IEEE/ANSI standards and customer specs.
• Support factory testing and field issues with technical root-cause analysis.
• Mentor junior engineers and drive engineering standardization.

Skills

Electromagnetic design

Core sizing

Winding configurations

Loss optimization

IEEE/ANSI standards

Analytical skills

Team collaboration

ANSYS Maxwell

COMSOL Multiphysics

MATLAB/Python

Education

Bachelor's degree in Electrical Engineering

Master's degree in Electrical Engineering or related

Tools

ANSYS Maxwell

COMSOL Multiphysics

MATLAB

Python

Excel

Job description

Senior Electrical Design Expert – EHV Power Transformers

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

1. 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.
• 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.
• 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 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.

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