Design Engineer Electrical
Resume:
Jack B. Johnston
*** *** ****** **** ****, Roanoke, VA 24012
**********@**********.***
Professional Experience
Design Engineer, Ermco – ECI, Greeneville, TN December 2018 - Present
Designed four new product lines for 750 kVA – 1000 kVA pole mounted bushings. Performed all thermoset research. Conducted and passed all ANSI testing. Designed the manufacturing equipment. Organized the production process. Came in $60 k under budget. Secondary projects included circuit breakers, expulsion fuses, lightning arrestors, and the development of fire-retardant wildlife protectors.
Dry Type Transformer Lead Engineer, Shenda Electric, Zhejiang, China August 2016 – November, 2018
Repaired and rebuilt failed dry-type transformers in Montreal, Canada. Replaced control and protection components to comply with CSA standards. Analyzed breaker TRV’s and full-load starting of pump motors. Performed field testing to verify successful rebuilds and installation. Re-wrote maintenance and operation procedures. Trained Shenda engineers on dielectrics. Electrical and mechanical design of small liquid transformers. Control circuits.
Technical Director of SGB satellite operation, SGB USA, Inc., Louisville, OH October 2015 – April 2016
Built a quote system to handle a wide range of magnetic requests. Built a system to handle parts, service, and warrantee. Prepared capital expenditure projects. Promptly addressed wind tech field questions and concerns from the field. Resolved backlog of factory and field failures to hold down warrantee costs and improve customer relations. Checked and approved cast coil designs sent from Regensburg, Germany. Translated design documentation from Deutsch to English then issued translated drawings to manufacturing. Managed the test lab, maintained calibration records, and resolved test issues.
Electrical Engineer, Virginia Transformer Corporation, Roanoke, VA April 2015 – October 2015
Performed R&D testing on insulation materials. Cut insulation costs on high BIL units. Created the DOE 2016 Matrix in preparation for the new efficiency standards. Designed UniCLAD’s through 10 MVA, up to 200 kV BIL on the primary and 95 kV BIL on the secondary. Wrote heat run test procedures for the Chihuahua, Mexico factory. Designed MV liquid transformers up to 30 MVA.
Design Engineer, Jefferson Electric, Reynosa, Mexico January 2015 – March 2015
Designed 600 V class elevator transformers and 12 pulse rectifier transformers remotely as the company re-located manufacturing from Franklin, Wisconsin to Reynosa, Mexico. Trouble-shot database and code problems. Resolved history of heat run failures on high k-factor units. Communicated manufacturing and test instructions to the Reynosa, Mexico factory.
Development Engineer, Howard Industries, Ellisville, MS December 2012 – August 2014
Set up a new open wound transformer product line. Wrote the open wound design program. Wrote all dry-type design technical standards (TS). Created the manufacturing procedures (MP), preventative maintenance procedures (PMP), and safety procedures (SP). Created production flow charts. Trained liquid engineers on open wound transformer designs, materials, and processes. Trained winders on comb and layer windings. Created bus assembly optimization standards.
Caretaker February 2012 – November 2012
Cared for completely paralyzed brother until death.
Senior Design Engineer, Schaffner MTC, Wytheville, VA February 2010 – February 2012
Designed 12 and 24 pulse rectifier transformers, interphase transformers, air and iron core reactors, and designed new coils for transformer rebuilds. Expanded the Navy product line. Expanded the UL file. Managed all CSA inspections. Obtained ABS certification. Created test databases to improve design reference data. Performed return on investment analysis on manufacturing equipment purchases. Revised and corrected designs for the Shaffner Shanghai, China factory.
Senior Design Engineer, ABB (Asea Brown Boveri), Bland, VA July 1991 – January 2010
Grew international business from $1 M/year to over $8 M/year over a four-year period. Engineering team leader for GE and international customer groups. Designed open-wound, vacuum cast, DyniCAST, and Resibloc single and three phase transformers in the range of 50 kVA – 30 MVA (120 V – 36 kV). The design scope included rectifier transformers, series-multiples, network-transformers, pad mounts, retrofits, isolation transformers, wind turbine transformers, excitation transformers, mining transformers, zigzags, and autotransformers. PG (Product Group) open-wound domain expert. Performed bench mark analysis for the General Manager. Quoted projects through 3.2 million dollars. The CSA Certification file manager and CSA EEV program manager. Maintained test equipment calibration data for the CSA file. Performed factory and site failure analysis. Developed engineering and manufacturing procedures. Wrote CDS material technical standards. Developed control circuit wiring diagrams. Mechanical design of core and coil assemblies and 15 kV HV switches.
Drafting Trainee, ABB (Asea Brown Boveri), Bland, VA March 1991 – June 1991
Designed sheet metal parts. Created customer outline drawings. Rapidly got promoted.
Control Wire Assemblyman, Pemco, Inc., Bluefield, VA November 1990 – February 1991
Built mining power centers and motor starters according to job specifications. Wired control circuits, metering equipment, and circuit protection devices.
Customer Service Representative, Dixie Bearings. Vansant, VA September 1990 – November 1990
Serviced local mining companies and hydraulic shops through phone and counter sales of motors, pillow blocks, bearings, seals, etc. Constructing rebuild kits for mining equipment. Shipping and receiving.
Waiter, Fincastle Country Club, Bluefield, VA June 1983 – September 1990
Waited on tables. Set up banquets and receptions. Managed both full-time work and full-time college.
Education
Bachelor of Science, Electrical Engineering, Bluefield State College, Bluefield, WV 1989
Course Description: Advanced Circuit Analysis and Design, Electronics, PLC’s, Electrical Transmission and Distribution, Transformers, Motors, Control Circuits, Mechanics, and General Engineering.
Associates of Applied Science, Electrical Technology, Bluefield State College, Bluefield, WV 1987
Associates of Applied Science, Electronic Technology, Wytheville C. College, Wytheville, VA 1985
Skills & Personal Characteristics
Proficient in Microsoft Word, Excel, Power Point and Access.
OSHA training, 6S, Kaizen, and other lean management programs.
Highly proficient in AutoCAD. Experience with Bentley, SolidWorks and Pro E.
Proficient using multiple electrical test equipment.
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