Transforming Energy for America
6 World-Class Operations
The headquarters for our corporation is located a few miles away from the picturesque Blue Ridge Parkway in Roanoke, VA. Designed and constructed specifically to produce power transformers, the 145,000-square-foot manufacturing facility is state-of-the-art.
In December 2013, a new facility was developed 11 miles from the main plant in Troutville, where the tank fabrication, sandblasting, and paint process were relocated. The tank fabrication plant is equipped with a welding robot that delivers leak-free welds, downdraft sandblasting booth for safety, and an SP-10 finish per SSPC standards for premium paint adhesion. The paint system is an epoxy primer on an activated surface and a topcoat of polyurethane baked to a hard finish to prevent rusting. The plasma table has been fitted with an etching gun to mark the location of all accessories, thus eliminating missed parts. The cross ventilation keeps the air free of weld fumes for the safety of personnel. The tank walls are aligned with a laser to ensure uniform clearance of the coils from the tank wall. Dye penetrant and particle leak-checking technology are used for quality assurance.
All tank fabrication facilities were equipped with these improvements in 2013. The combined capacity of all plants is more than 1500 tanks per year. The teams are proud to work in a clean and safe factory with a Mod Factor of 0.9 – better than the industry standard.
The vapor-phase drying system was installed in 2015 at Roanoke to achieve optimum insulation dryness. The VPD system is automated; technicians can download the process parameters to their cell phones. It allows for two transformers to be processed simultaneously and achieves a vacuum level of .25 torr. A second core cutting machine was installed in 2015 to increase capacity and eliminate the possibility of a single point of failure.
The machine cuts a 26-inch-wide core; the edge burr level is typically less than 20 microns. This cutting process decreases power and eddy loss while also reducing sound level by 2 dB.
The core and coil assembly are laser-aligned to ensure uniform clearance from the coils on the tank wall. The DETC is also aligned using laser to guarantee smooth shaft rotation and minimal contact resistance. All floors of the plant were ground and sealed in 2015 to eliminate floor dust. Four winding machines were added to increase the capacity to build larger coils. The plant is equipped to manufacture 30 MVA base rating, 161 kV, 650 kV BIL as well as dry-type transformers to 10 MVA, 35 kV, 150 kV BIL.
A second test bay was added in 2015, allowing two units to test simultaneously. The impulse test capacity was increased to offer switching-wave impulse testing.
The net result of the improvements is long transformer life.
A core-building station with hydraulic lift was commissioned in 2019 to ensure minimum core handling and reduced losses.
VTCR – Roanoke, VA
The headquarters for our corporation is located a few miles away from the picturesque Blue Ridge Parkway in Roanoke, VA. Designed and constructed specifically to produce power transformers, the 145,000-square-foot manufacturing facility is absolutely state-of-the-art.
In December 2013, a new facility was developed 11 miles from the main plant on 25 acres of land; the tank fabrication, sandblasting and paint process were relocated there.Read More
Virginia Transformer - Troutville, VA
Virginia Transformer’s Troutville location opened in December 2013. Located approximately 11 miles from our Roanoke plant, it was originally developed as the new site for tank fabrication, sandblasting, and paint process. It has expanded over the years and now plays a key role in our supply chain and Integrated Power Module (IPM) production operations.Read More
VTCU – Pocatello, ID
VTC acquired its third plant in 2003 from UST West. The plant can produce 230 kV at 1050 kV BIL, making it the best-equipped plant of its range in North America.
The plant features five 25,000-square-foot bays. One bay contains winding and insulation. There are two core-cutting machines, providing full backup in case of machine failure. Both machines can cut up to 37 wide step-lap cores and produce burr levels of less than 20 micros, easily beating the industry-standard sound level of 55 dB. Losses are less than .25 percent of the MVA.Read More
GTC – Rincon, GA
The Georgia Power Transformer manufacturing facility, an affiliate of Virginia Transformer Corp, is located in Rincon, Georgia. It was built in 2009 by Efacec Energia. It uses the best engineering and design concepts available for shell transformers up to 1,400 MVA & 500 kV, core form up to 400 MVA & 525 kV, with a total capacity of 47,000 MVA.
Since acquiring the Rincon facility in January 2015, Georgia Transformer has been focused on strengthening the business and operations while keeping the foundations established by Efacec intact.Read More
VTCW Plant 1 – Chihuahua, Mexico
Located in Chihuahua, Mexico, the 82,000-square-foot plant is a state-of-the-art modern facility. Here, we custom design and manufacture small power transformers: dry-type transformers, VPI, UNIDIP, and UNIClad®, from 300 kVA up to 7,500 kVA (base rating), up to 34.5 kV; liquid-filled transformers, from 300 kVA up to 10,000 kVA (base rating), up to 34.5 kV; Padmount transformers, from 300 kVA up to 5,000 kVA, up to 34.5 kV. We ship three product lines: dry-type, renewable pad-mounted, and substation transformers to utilities and industrial markets in North and Central America.
Providing reliable, on-time, ready-to-ship small power transformers is part of our DNA at our Chihuahua, Mexico plant. It is a state-of-the-art transformer manufacturing facility that satisfies the most rigorous requirements in the industry, featuring three buildings designed and laid out for the best material and production flow.Read More
VTCW Plant 2 – Chihuahua, Mexico
Virginia Transformer’s second plant in Chihuahua and sixth in North America began production in October 2022 and was officially inaugurated in February 2023.
The new plant is the most technologically advanced transformer facility in North America and will further extend the company’s leadership in having the shortest lead times in the industry. Virginia Transformer can deliver a custom-made, state-of-the-art transformer in less than half the time of its competitors.Read More
Virginia Transformer India (VTI)
Virginia Transformer’s India location (VTI) originally opened in Mumbai in 2001 to complement the company’s design capabilities and help procure transformer materials from around the world. The VTI office has since moved to Delhi and employs over 100 highly trained engineers, technicians, and operational staff. The engineers participate in extensive training, and travel to our US plants to receive hands-on manufacturing experience and further enhance their transformer design knowledge.
VTI provides substantial support to Virginia Transformer’s North American facilities by utilizing its strategic location to source from overseas vendors. All materials acquired by VTI undergo a rigorous inspection before approval, ensuring that VTC’s transformers are made with only the highest-quality components.