Senior Mechanical Design & Short-Circuit Withstand Expert – Power Transformers

Virginia Transformer Corp; Muscle Shoals (AL); On-site; USD 120,000 - 180,000; Full time

Job summary

Virginia Transformer Corp in Muscle Shoals, AL, seeks a Senior Mechanical Design & Short-Circuit Withstand Expert to lead mechanical strength analyses for large oil-immersed transformers up to 250 MVA and 230 kV. You will drive windings, tanks, and core-and-coil assemblies toward robust, fault-tolerant designs.

Ideal candidates bring 12–15+ years in transformer mechanical design, advanced FEA skills (ANSYS/Abaqus), and a proven track record in supporting manufacturing, testing, and reliability

Qualifications

• Bachelor's degree in Mechanical Engineering required, with advanced degrees preferred.
• 12–15+ years of mechanical design/structural analysis experience with large transformers.
• Experience with short-circuit withstand calculations and transformer windings.

Responsibilities

• Short-Circuit Withstand: calculate axial/radial winding forces during faults.
• Winding mechanical strength: assess buckling, hoop stress, and clamping.
• Core-and-coil design: analyze core frames, yoke beams, and supports.
• Lead internal structures: evaluate leads, clamps, supports under fault loads.
• Tank structural analysis: vacuum/pressure, welding, and deformation checks.
• Seismic/transport/dynamic load analysis and verification.
• FEA modeling validation and cross-functional collaboration.

Education

Bachelor's degree in Mechanical Engineering

Master's degree in Mechanical Engineering (preferred)

PhD in Mechanical Engineering (advantage)

Tools

ANSYS Mechanical

Abaqus

Finite Element Analysis (FEA)

Job description

Senior Mechanical Design & Short-Circuit Withstand Expert – Power Transformers

Location: Muscle Shoals, Alabama

Position Type: Full-Time | Onsite

Department: Engineering – Power Transformer Design

Reports To: Senior Engineering Manager – Power Transformer Design

On the Heels of Achieving 3X Growth, Virginia Transformer Is Hiring to Do It Again!

Virginia Transformer is the largest U.S.-owned manufacturer of power transformers in North America, and we're strategically building our team for our next 3X growth cycle.

As a privately held, organically growing company, we thrive on innovation, nimbleness, and tenacity. We are an engineering-driven organization manufacturing premium-quality power transformers with some of the shortest lead times in the industry.

Our continued expansion includes a new manufacturing facility in Muscle Shoals, Alabama, where we are building a high-performance team to support our next phase of growth.

This is an intense, fast-paced, and rewarding environment. We are highly selective, and this opportunity is not for everyone.

If you have the drive, grit, technical expertise, and determination to perform at the highest level — and want to grow your career 3X alongside our company — we want to hear from you.

One Team. One Mission. One Source.

Position Summary

Virginia Transformer is seeking a highly experienced Senior Mechanical Design & Short-Circuit Withstand Expert to join our engineering team at our new manufacturing facility in Muscle Shoals, Alabama.

This senior-level technical position will lead mechanical strength analysis, structural validation, and short-circuit withstand assessments for large oil-immersed power transformers rated up to 250 MVA and 230 kV class.

The successful candidate will serve as a principal technical expert responsible for ensuring the mechanical integrity and structural reliability of transformer windings, core-and-coil assemblies, clamping systems, internal leads, tanks, and supporting structures.

This position requires extensive hands-on experience in transformer mechanical design, electromagnetic force calculations, winding stability, finite element analysis (FEA), and structural engineering.

The ideal candidate will bring proven expertise in designing and validating transformers capable of withstanding electrical fault conditions, manufacturing stresses, transportation loads, and seismic requirements.

Key Responsibilities

Short-Circuit Withstand & Electromagnetic Force Analysis

• Independently calculate and validate axial and radial electromagnetic forces acting on transformer windings during short-circuit events.
• Evaluate peak asymmetrical short-circuit currents, leakage magnetic flux, and resulting mechanical loads.
• Analyze radial compression, tensile forces, axial thrust, and winding displacement.
• Evaluate short-circuit forces for two-winding, three-winding, and autotransformer configurations.
• Assess critical operating conditions, winding combinations, and tap positions.
• Develop standardized short-circuit force calculation and mechanical verification methodologies.

Winding Mechanical Strength & Stability

• Analyze winding radial buckling, hoop stress, conductor deformation, and structural stability.
• Evaluate axial compression, end thrust, winding tilting, telescoping, and displacement risks.
• Determine appropriate winding clamping forces and pre-compression requirements.
• Assess pressure rings, clamping plates, tie rods, and supporting structures.
• Evaluate insulation compression, creep, shrinkage, and mechanical relaxation.
• Recommend improvements to winding construction, conductor sizing, and support arrangements.

Core-and-Coil Mechanical Design

• Evaluate structural integrity of transformer core-and-coil assemblies.
• Analyze core clamping frames, yoke beams, tie rods, and active-part support systems.
• Assess mechanical stresses during manufacturing, lifting, handling, and transportation.
• Evaluate structural deformation, vibration, and mechanical stability.
• Investigate mechanical failures, component movement, and assembly-related issues.
• Partner with engineering and manufacturing teams to improve structural reliability.

Lead Support & Internal Mechanical Structures

• Evaluate electromagnetic forces acting on high-current and high-voltage leads.
• Analyze mechanical loading on lead supports, brackets, clamps, and insulating structures.
• Assess lead movement, vibration, and mechanical stability under fault conditions.
• Validate support spacing, structural strength, and conductor connections.
• Coordinate with dielectric engineering to maintain electrical clearances and insulation performance.

Transformer Tank Structural Analysis

• Perform structural analysis of transformer tanks under full-vacuum and positive-pressure conditions.
• Evaluate tank walls, covers, bases, stiffeners, flanges, and welded connections.
• Analyze structural stresses, deflections, and buckling risks.
• Validate structural integrity during oil filling, vacuum processing, and pressure testing.
• Conduct finite element analysis of complex tank structures.
• Recommend structural improvements that optimize material usage without compromising mechanical strength.

Seismic, Transportation & Dynamic Load Analysis

• Perform seismic load calculations based on applicable customer and project requirements.
• Evaluate transformer tanks, active parts, bushings, and accessory supports under seismic conditions.
• Analyze transportation acceleration, lifting, jacking, and handling loads.
• Assess vibration, dynamic loading, and structural stability.
• Recommend reinforcement and support arrangements to meet mechanical withstand requirements.

Finite Element Analysis & Structural Simulation

• Develop and validate FEA models for transformer windings, clamping systems, tanks, and structural assemblies.
• Perform static structural, buckling, nonlinear contact, and dynamic analyses.
• Evaluate stresses, strains, deflections, and mechanical stability.
• Validate analytical calculations through simulation and available test data.
• Establish standardized modeling assumptions and verification procedures.
• Improve engineering accuracy, efficiency, and structural design performance.
• Provide independent technical reviews of mechanical designs and structural calculations.
• Verify winding clamping systems and short-circuit withstand capability.
• Support factory inspections, mechanical testing, and failure investigations.
• Investigate winding deformation, tank distortion, and transportation-related damage.
• Lead technical root-cause analysis and recommend corrective actions.
• Collaborate with electromagnetic, dielectric, mechanical design, and manufacturing engineering teams.
• Mentor engineers in mechanical analysis, structural design, and short-circuit withstand requirements.
• Participate in customer technical reviews and communicate critical engineering risks.
• Recommend technical holds on designs that do not demonstrate adequate mechanical withstand capability, consistent with engineering approval procedures.

Required Qualifications

Education

• Bachelor's degree in Mechanical Engineering or a closely related engineering discipline required.
• Master's degree in Mechanical Engineering, Structural Engineering, or Applied Mechanics strongly preferred.
• PhD in Mechanical Engineering, Structural Mechanics, or a related discipline is an advantage when combined with practical transformer experience.

Professional Experience

• 12–15+ years of progressive experience in mechanical design, structural analysis, or mechanical withstand engineering for large power transformers.
• Preferably 8–10 years of direct experience performing transformer winding mechanical strength and short-circuit withstand calculations.
• Demonstrated experience working with power transformers rated 100 MVA and above.
• Strong preference for experience with 230 kV class or higher-voltage transformers.
• Proven expertise in winding axial and radial force calculations, buckling analysis, and clamping system design.
• Experience with transformer tank vacuum and pressure calculations.
• Extensive hands‑on experience using finite element analysis for mechanical and structural validation.
• Direct experience supporting transformer manufacturing, mechanical inspections, testing, and failure investigations.
• Demonstrated ability to independently evaluate complex transformer mechanical designs and recommend technical improvements.

Required Technical Expertise

Candidates must demonstrate advanced proficiency in the following areas:

• Short-Circuit Withstand: Electromagnetic force calculations, axial/radial winding forces, peak asymmetrical loading, and mechanical withstand verification.
• Winding Mechanics: Radial buckling, hoop stress, axial compression, winding clamping, insulation creep, and mechanical stability.
• Structural Engineering: Strength of materials, structural mechanics, welded and bolted connections, tank pressure/vacuum analysis, and seismic loading.
• Finite Element Analysis: ANSYS Mechanical, Abaqus, or equivalent FEA software; nonlinear structural analysis, buckling, contact mechanics, and modal analysis.
• Transformer Manufacturing: Winding compression, core‑and‑coil assembly, tank fabrication, welding, mechanical inspections, and transportation requirements.

Industry Standards & Compliance

Working knowledge of applicable transformer and structural engineering standards, including:

• IEEE C57.12.00 – General Requirements for Liquid-Immersed Transformers
• IEEE C57.12.90 – Test Code for Liquid-Immersed Transformers
• IEEE C57.12.10 – Requirements for Liquid-Immersed Power Transformers
• IEEE C57.109 – Transformer Through-Fault Current Duration
• IEC 60076-5 – Ability to Withstand Short Circuit
• IEEE 693 – Seismic Design and Qualification of Substation Equipment, when applicable
• Applicable AWS welding standards and ASTM material specifications
• Exceptional analytical and mechanical problem-solving abilities.
• Advanced understanding of transformer short-circuit failure mechanisms.
• Strong engineering judgment and ability to identify mechanical design risks.
• Demonstrated success solving complex structural and manufacturing challenges.
• Ability to work independently and make technically sound engineering recommendations.
• Strong communication and cross-functional collaboration skills.
• Experience mentoring and developing mechanical engineering talent.
• Commitment to engineering excellence, product reliability, and continuous improvement.
• Ability to thrive in a high-performance, fast-paced manufacturing environment.

Key Performance Expectations

Success in this position will be measured by:

• Verified mechanical strength and short-circuit withstand capability of transformer designs.
• Prevention of winding buckling, axial displacement, and structural deformation.
• Reliable winding clamping and long-term mechanical stability.
• Successful tank vacuum, pressure, and structural validation.
• Compliance with applicable seismic and transportation requirements.
• Reduction in mechanical design deviations, failures, and manufacturing issues.
• Timely completion of mechanical calculations, design reviews, and technical verification.
• Continuous improvement in transformer mechanical design quality and engineering productivity.

Why Join Virginia Transformer?

Virginia Transformer is entering another significant growth phase, creating opportunities for experienced engineering professionals to make a direct impact on the future of power transformer manufacturing.

At our new Muscle Shoals facility, you will have the opportunity to contribute to the development of a growing manufacturing operation, influence critical transformer designs, and work alongside engineering and manufacturing leaders committed to technical excellence.

We are looking for proven experts who want to solve challenging engineering problems, drive innovation, and help build the next generation of American power transformer manufacturing.

This is a full-time, onsite position in Muscle Shoals, Alabama.

Ready to grow your career 3X?