Electrical Design Engineer

Virginia Transformer Corp

Muscle Shoals (AL)

On-site

USD 90,000 - 130,000

Full time

3 days ago

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Job summary

Virginia Transformer Corp in Muscle Shoals, Alabama is seeking an Electrical Design Engineer for power transformers. The role focuses on electrical and electromagnetic design of oil-immersed transformers for utility, industrial, and power generation applications.

Responsibilities include core sizing, winding design, impedance and loss calculations, as well as design documentation, manufacturing support, and collaboration with cross-disciplinary engineering teams to deliver reliable,

Qualifications

Bachelor's degree in Electrical Engineering is required.
3–7 years of electrical design experience, preferably in oil-immersed transformers.
Experience with core sizing, winding design, impedance, and loss calculations.
Familiarity with IEEE C57 standards and transformer design documentation.

Responsibilities

Perform core sizing and magnetic circuit calculations.
Design HV/LV/tertiary windings and determine turns, conductor sizes, and dimensions.
Calculate winding resistance, losses, and current density.
Evaluate impedance for winding combinations and tap positions.
Coordinate with dielectric, thermal, and mechanical design requirements.
Prepare design data sheets, BOMs, and documentation for manufacturing.
Support factory testing and engineering change notices.
Maintain design calculation records and verification.

Skills

Core sizing

Magnetic circuit

Winding design

Impedance calculation

Loss calculations

Electrical design

Engineering calculations

Multidisciplinary teams

IEEE standards

Customer specifications

Education

Bachelor's degree in Electrical Engineering

Master's degree in Electrical Engineering or Power Engineering is preferred

Tools

Microsoft Excel

MATLAB

Python

AutoCAD

ERP systems

Job description

On the heels of achieving 3X growth, Virginia Transformer is hiring to do it again!

We’re strategically building our team for the next 3X growth cycle — a phase that is both intense and incredibly rewarding. We’re highly selective about who joins us, because this journey isn’t for everyone.

If you have the drive, grit, and expertise to perform at a high level — and you want to grow your career 3X alongside the Company’s growth — we’d love to talk.

Who We Are

Virginia Transformer is the largest U.S.-owned producer of power transformers in North America, and we’ve been able to grow the past 50-plus years through an unwavering focus on delivering for our customers. We’re more than 6,000 people strong and are known throughout the industry for being an engineering company that makes premium quality transformers in the shortest lead times.

As a privately held, organically growing company, we thrive on nimbleness, innovation, and tenacity.

Join Our Team

If you love the thrill of securing the U.S. electric grid, enabling all manufacturing in the country, and the energy of a fast-moving train — this is the place for you. We train hard, grow together, and lead with purpose. Every transformer we build is custom, every challenge unique, and every team member essential.

We’re looking for those ready to lead, fueled by commitment, and driven by impact. We are growing so fast that all our available roles are not yet posted, so let us know if you are interested and we will follow-up.

Join a Company Built to Grow – Powered by People

At Virginia Transformer, we’re not just manufacturing custom transformers — we’re building power solutions that move the world. As a privately held, organically growing company, we thrive on momentum, innovation, and grit.

If you love the thrill of manufacturing, the strategy of an endurance race, and the energy of a fast-moving train — this is your track. We train hard, grow together, and lead with purpose. Every transformer we build is custom, every challenge unique, and every team member essential.

We’re looking for those ready to lead, fueled by commitment, and driven by impact. One team. One mission. One source.

Job Title: Electrical Design Engineer – Power Transformers

Location: Muscle Shoals, Alabama

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.

Key Responsibilities

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.
Calculate no-load losses and excitation current.
Evaluate core saturation and overexcitation requirements.
Coordinate core design with manufacturing and mechanical engineering teams.
Support core design optimization for losses, material utilization, and cost.

Transformer Winding Design:

Perform detailed electrical design of HV, LV, tertiary, and regulating windings.
Determine winding turns, conductor sizes, current density, and winding dimensions.
Calculate winding resistance and conductor losses.
Evaluate parallel conductor arrangements and circulating-current effects.
Coordinate winding geometry with dielectric, thermal, and mechanical design requirements.
Support optimization of copper consumption, winding dimensions, and manufacturing efficiency.

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.

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.
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.

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.

Electrical Design Documentation:

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

Manufacturing and Factory Testing Support:

Provide technical support during core manufacturing and winding production.
Review winding dimensional deviations and evaluate their impact on performance.
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.

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.

Key Qualifications

Education:

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

Professional Experience:

Minimum 3–7 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.

Preferred Skills & Technical Competencies

Transformer Electrical Design: