Transformer Electrical & Mechanical Design Engineer

Electrotherm (India) Limited; Ahmedabad District; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Electrotherm (India) Limited in Ahmedabad seeks a Transformer Electrical & Mechanical Design Engineer with 5+ years of experience to design power and distribution transformers meeting customer specs, standards, and cost targets.

You will work on winding, core, insulation coordination, thermal design, and manufacturing support, using AutoCAD/SolidWorks/Creo and related tools to deliver robust designs for the steel and metals industry.

Qualifications

• Electrical design knowledge for transformers: rating, voltage/current, turns, insulation, losses, impedance.
• Winding design: conductor dimensions, number of turns, cooling, insulation thickness.
• Core design: material grade, dimensions, no-load loss.
• Insulation coordination: barriers, oil/solid insulation distances.
• Thermal design: winding oil temperature rise, cooling ducts, radiators, ONAN/ONAF/OFAF/OFWF.
• Short-circuit and mechanical strength calculations: verify forces and withstand fault conditions.
• Mechanical design: tank, cover, radiators, terminal arrangements.
• Structural calculations: tank strength, lifting and transport loads, seismic constraints.
• Bushing and accessory selection: HV/LV bushings, OLTC/DETC, CTs, PRD, gauge equipment.
• Drawings and documentation: GA drawings, BOMs, specs, nameplates.
• Standards compliance: IEC 60076, IEEE/ANSI C57, IS 2026.
• Design verification: losses, impedance, temperature rise, dielectric levels.
• Manufacturing support: coordinate with windings, core, assembly, insulation teams.
• Testing support: review test results like ratio, resistance, losses, impedance.
• Technical troubleshooting: investigate failures and implement corrective actions.
• Customer/project support: respond to specs and comments; support tender teams.
• Cost optimization: improve materials without compromising performance.
• Design tools: AutoCAD/SolidWorks/Creo, Excel, 2D/3D CAD, FEA, ERP/PLM.

Responsibilities

• Electrical design: calculate transformer rating, voltage/current levels, turns ratio, winding arrangement, conductor sizing, current density, flux density, core area, losses, impedance, efficiency, temperature rise, insulation levels, short-circuit withstand, clearances, creepage distances, and dielectric performance.
• Winding design: select winding type (layer, helical, disc, continuous-disc, foil); determine conductor dimensions, turns, dimensions, cooling ducts, insulation thickness, transposition requirements.
• Core design: select core material and grade, core diameter, limb/yoke dimensions, flux density, core weight, no-load loss, and excitation current.
• Insulation coordination: design insulation for impulse, power-frequency, induced-voltage, partial-discharge; set barriers, oil distances.
• Thermal design: evaluate winding/oil temperature rise, cooling ducts, radiators, ONAN/ONAF/OFAF/OFWF.
• Short-circuit and mechanical strength calculations: verify electromagnetic forces and withstand faults.
• Mechanical design: layout tank, cover, conservator, radiator, core-frame, gripping, terminal arrangements, bus duct.
• Structural calculations: assess tank strength, lifting/transport loads, seismic requirements.
• Bushing/accessory selection: choose HV/LV bushings, OLTC/DETC, CTs, PRD, etc.
• Drawings/documentation: prepare GA drawings, winding drawings, BOMs, specs.
• Standards compliance: ensure IEC 60076, IEEE/ANSI C57, IS 2026 compliance.
• Design verification: review losses, impedance, noise, temperature rise, dielectric levels.
• Manufacturing support: collaborate with production teams to resolve issues.
• Testing support: review tests (ratio, resistance, losses, impedance, temperature rise).
• Customer/project support: respond to customer comments and support tender teams.
• Cost optimization: optimize components without sacrificing reliability.
• Design tools: use AutoCAD/SolidWorks/Creo, Excel, CAD, FEA, thermal tools, ERP/PLM.

Job description

Electrotherm (India) Limited, founded in 1983, is a technology-driven engineering company focused on innovation and customer-centric product development. The company designs and manufactures high-capacity furnaces, metal refining converters, ladle furnaces, and high-speed continuous casting machines that enhance steel quality and productivity. Electrotherm also develops mechanized charging systems, advanced plant automation solutions, and fume capturing and de-dusting systems to make steel plants cleaner and more efficient. Guided by the mission “Always innovate for a better tomorrow,” the organization emphasizes in-house research and development and continuous improvement in its solutions for the steel and metals industry.

Job Title: Transformer Electrical & Mechanical Design Engineer.

Industry: Transformer and Switch gear Manufacturing

Department: Design

Reports To: Design Head

Experience: 5+ Years

A Transformer Electrical & Mechanical Design Engineer is responsible for designing power/distribution transformers so they meet customer specifications, applicable standards, manufacturing constraints, performance guarantees, and cost targets.

Typical responsibilities include:

• Electrical design: calculate transformer rating, voltage/current levels, turns ratio, winding arrangement, conductor sizing, current density, flux density, core area, losses, impedance, efficiency, temperature rise, insulation levels, short-circuit withstand, clearances, creepage distances, and dielectric performance.
• Winding design: select winding type such as layer, helical, disc, continuous-disc, or foil; determine conductor dimensions, number of turns, radial/axial dimensions, cooling ducts, insulation thicknesses, and transposition requirements.
• Core design: select core material and grade, core diameter, step-lap arrangement, limb/yoke dimensions, flux density, core weight, no-load loss, and excitation current.
• Insulation coordination: design insulation for impulse, power-frequency, induced-voltage, and partial-discharge requirements; determine barriers, cylinders, spacers, end insulation, lead clearances, and oil/solid insulation distances.
• Thermal design: evaluate winding and oil temperature rise, cooling ducts, heat dissipation, radiator requirements, and cooling systems such as ONAN, ONAF, OFAF, or OFWF.
• Short-circuit and mechanical strength calculations: verify radial and axial electromagnetic forces and ensure windings, clamping systems, leads, and support structures can withstand fault conditions.
• Mechanical design: develop tank, cover, conservator, radiator, core-frame, clamping, lifting, jacking, foundation, terminal arrangement, cable box, bus duct, and accessory layouts.
• Structural calculations: check tank strength, vacuum withstand, pressure withstand, lifting loads, transportation loads, seismic requirements where applicable, and mechanical stresses.
• Bushing and accessory selection: select HV/LV bushings, OLTC/DETC, CTs, PRD, Buchholz relay, oil level indicator, temperature indicators, marshalling box, valves, gauges, and other customer-specified accessories.
• Drawings and documentation: prepare or review GA drawings, winding drawings, core-coil assembly drawings, tank fabrication drawings, connection diagrams, BOMs, material specifications, nameplate details, and manufacturing documents.
• Standards compliance: ensure designs comply with applicable standards such as IEC 60076, IEEE/ANSI C57, IS 2026, customer specifications, and internal engineering practices.
• Design verification: review guaranteed losses, impedance, noise, temperature rise, dielectric levels, dimensions, weights, oil quantity, transport limitations, and overall performance before design release.
• Manufacturing support: work with winding, core, assembly, tank fabrication, insulation, and production teams to resolve manufacturing issues and implement design improvements.
• Testing support: review routine, type, and special test results including ratio, resistance, losses, impedance, temperature-rise, impulse, induced-voltage, applied-voltage, partial-discharge, and sound-level tests.
• Technical troubleshooting: investigate test failures, excessive losses, high temperature rise, abnormal impedance, dielectric failures, vibration, leakage, or mechanical problems and implement corrective actions.
• Customer and project support: review technical specifications, prepare clarification documents, attend design-review meetings, respond to customer comments, and support tender/project engineering teams.
• Cost optimization: optimize conductor, core steel, insulation, oil, tank steel, radiators, and accessories without compromising reliability or guaranteed performance.
• Design tools: commonly use transformer-design software together with AutoCAD/SolidWorks/Creo, Excel, 2D/3D CAD, FEA tools, thermal-analysis tools, and ERP/PLM systems.

Salary: No salary bar for right candidate