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Ayers Transformer Consulting LLC

January 2012 – Present Waxhaw, NC (Charlotte Area)
Ayers Transformer Consulting LLC provides services to the users and manufacturers of power transformers used in the utility, industrial, construction and transit industries. Particular areas of experience include transformer core form design from 75 kVA, 30 kV BIL to 200+ MVA, 1050 kV BIL in both rectangular and circular configurations. Specific transformer types and applications include substation, unit subs, padmount, grounding transformers, rectifier transformers, phase-shifting transformers, wind and solar energy units, harmonic loaded, retrofit applications, autotransformers, step-up transformers and motor starting transformers. Services offered include transformer specification development, design reviews, in-process inspections, factory test witness, product installation supervision, manufacturer compliance auditing, design optimization, failure analysis, repair options and expert testimony.


Vice President, Engineering and Manufacturing

Pacific Crest Transformers

April 2005 – December 2011 Medford, Oregon Area
Manufacturer of substation, unit subs, padmount, grounding transformers, rectifier transformers, phase-shifting transformers, wind and solar energy transformers, autotransformers, step-up transformers and motor starting transformers involving harmonic loading and retrofit applications.


Plant Manager

VTCU – Virginia Transformer Corp.

November 2004 – April 2005 Pocatello, Idaho Area
Subsidiary of Virginia Transformer (VTC) that manufactures and repairs large power transformers. Interim assignment to effect changes to improve quality and profitability and advance the technical capabilities of the technical organization.


Quality Manager

Virginia Transformer Corp

1998 – 2004 Roanoke, Virginia Area
Privately Held; 501-1000 employees; Utilities industry
$50 Million international manufacturer of dry type and liquid filled transformers and services. As part of President’s staff I lead the efforts to improve, strengthen and expand the Quality Department, Test Operations and the Field Service organization.


Engineering Manager

Delta Star

1997 – 1998 Lynchburg, Virginia Area
Privately Held; 201-500 employees; Electrical/Electronic Manufacturing industry
$60 Million manufacturer of liquid filled HV power transformers for the utility market. As the head of engineering I worked to improve the capability and productivity of the Engineering Department.


Director of Engineering

Smit Transformer, Inc.

1993 – 1995 Charleston, South Carolina Area
A Dutch manufacturer of large power transformers that purchased the Westinghouse repair operation and pursued both repair and manufacturing of new transformers.


Engineering Manager – Charleston Transformer Repair Center

Westinghouse Repair Services Division

1992 – 1993 Charleston, South Carolina Area
Newly created power transformer repair facility targeted at the utility marketplace and handled transformers to 300 MVA and 345 kV, 1050 BIL. Re-engineered and upgraded failed transformers and performed failure analysis to try and determine root cause.


Project Manager and Division Transformer Engineering Manager

Westinghouse Repair Services Division

1990 – 1991 Greater Pittsburgh Area
Brought transformer repair plant from concept to fully operational status within two years. The result was a recognized world-class facility with capabilities not normally found in repair plants. Also supported other repair operations with transformer design support and failure analysis support.


Design Engineer, Design Manager, Test Manager & Quality Manager

Westinghouse Medium Power Transformer Division

1969 – 1984 Sharon, Pennsylvania Area
Trained and applied the knowledge of transformers to design, analysis, testing and field problem solutions.