Senior Controls Engineer

Electra; Boulder (CO); On-site; USD 105,000 - 140,000; Full time

Benefits offered by this job

100% paid medical premiums

401k with matching contributions

Annual HSA contributions

Job summary

A leading technology firm is seeking a Senior Controls Engineer focused on designing and managing control systems for revolutionizing iron production. The ideal candidate will have substantial experience in PLC programming, instrumentation, and industrial electrical design. Responsibilities include full lifecycle control system design, collaboration with cross-functional teams, and opportunities for project leadership. This position offers a competitive salary range of $105,000-140,000, extensive benefits, and a strong commitment to safety culture.

Qualifications

• 8+ years of industry experience working on controls and data acquisition.
• 3+ years of experience with PLC programming, ideally Siemens.
• Experience with safety analysis methodologies like FMEA, PHA, and HAZOP.

Responsibilities

• Design, develop, and maintain electrical and control systems for iron production.
• Collaborate with engineering and operations teams to define system requirements.
• Lead integration efforts for new equipment and oversee installations.

Skills

PLC programming

Instrumentation knowledge

High- and low-voltage design

Industrial automation protocols

Project management

Education

8+ years of industry experience

Tools

Siemens S7

SolidWorks Electrical

Ignition HMI

Job description

We're transforming one of the world’s oldest industries with cutting-edge technology and an innovative approach. Backed by top-tier investors and recognized by Time as one of the "best Inventions of 2024" and Fast Company as one of 2024's "Next Big Things in Tech", Electra is scaling rapidly, and we're looking for bold, driven individuals to help us reshape the future of iron production. If you're ready to make a real impact in a company that's redefining heavy industry for a cleaner, smarter world, we want to hear from you.

What you will do

As a Senior Controls Engineer, you will focus on designing and building data acquisition and process control systems for chemical processing. These systems will integrate instrumentation, controls, plumbing, fluid power, and solids handling to enable novel electromechanical and metallurgical processes for clean iron production.

Responsibilities

• Design, develop, and maintain electrical, instrumentation, and control (EIC) systems for iron-production processes from concept through detailed design, fabrication, commissioning, and handover
• Own the full lifecycle of control system design, including P&IDs, I/O lists, control narratives, instrumentation specifications, electrical schematics, panel layouts, and network architectures
• Ensure all control systems are efficient, reliable, safe, compliant with applicable codes/standards (e.g., NEC, ISA, IEC), and aligned with site EHS requirements
• Collaborate cross-functionally with process engineering, mechanical systems, operations, and R&D teams to define system requirements and control strategies
• Lead integration efforts for new and existing equipment, including PLC/HMI/SCADA system architecture and control strategies
• Oversee and perform installation, configuration, commissioning, and site acceptance testing (SAT) of control systems
• Conduct system testing, tuning, loop checks, and validation to ensure optimal and stable process performance
• Identify opportunities for process optimization, advanced control, alarm management, and system reliability improvements
• Program and troubleshoot Siemens S7 PLCs (TIA Portal), Ignition HMI & SCADA, and associated communication networks
• Develop, maintain, and review electrical design packages in SolidWorks Electrical, including control panel designs, wiring diagrams, and bill of materials
• Specify and source instrumentation and electrical equipment (sensors, transmitters, motors, drives, MCC components, etc.) to meet process and project requirements
• Autonomously lead engineering projects or small multi-disciplinary teams, including scheduling, budgeting, technical decision-making, and vendor management
• Troubleshoot complex electromechanical systems, perform root cause analysis, and execute corrective/preventive actions
• Apply industry-standard safety analysis methodologies such as FMEA, PHA, and HAZOP to effectively manage risks
• Develop and maintain engineering documentation, including control narratives, cause-and-effect matrices, test plans, operating procedures, and safety protocols
• Read, understand, and comply with all workplace health and safety policies, safe work practices, and company policies and procedures
• Perform other duties as assigned by supervisor in a rapidly evolving startup environment

What we need you to bring to the team

• 8+ years of industry experience working on controls and data acquisition (excludes internships, co-ops, and other school projects)
• 3+ years of experience with PLC programming, including Ladder Logic and structured text (Siemens preferred)
• Advanced experience with instrumentation such as voltage, amperage, temperature, pressure, level, weight, and flow
• Strong working knowledge of high- and low-voltage electrical design, electrical troubleshooting, and industrial power distribution
• Proficiency with industrial automation communication protocols such as Modbus, Profibus, Ethernet, RS485, etc.
• In-depth knowledge of industrial control system design principles, instrumentation specification, P&IDs, and ISA/IEC standards
• Experience implementing LOTO procedures, arc-flash boundaries, electrical safe-work practices, and other industrial electrical safety programs
• Self-starter with strong autonomy; capable of working with minimal supervision in a fast-paced environment
• Ability to work in a multi‑disciplinary team environment and adapt quickly to changing processes and responsibilities
• Strong organizational, project management, and time management skills
• Experience and/or interest in mentoring more junior control systems engineers
• Proficiency with, or ability to quickly learn, Microsoft Office suite of programs including Word, Excel, PowerPoint, Outlook, OneDrive, and SharePoint

What we want you to bring to the team

• 10+ years of industry experience working on controls and data acquisition (excludes internships, co‑ops, and other school projects)
• Proficiency with Siemens S7 (TIA portal), Ignition, SolidWorks Electrical, and SQL databases
• Experience in chemical processing, industrial manufacturing, pilot‑plant operations, or continuous/batch process industries
• Experience with control panel design per UL 508A, hazardous area classification, and instrument selection for chemical environments

Compensation

• The anticipated starting pay range for this position is $105,000-$140,000 and may be more or less depending upon skills, experience, and education.

Benefits For You

• 100% paid premiums across all medical, dental, vision, telemedicine, short‑term disability, long‑term disability, and basic life insurance plans
• Reasonable use PTO
• $1,800 in annual employer HSA contributions (health savings account)

Benefits For Your Family

• 100% paid premiums across all medical, dental, vision, and telemedicine plans
• 12 weeks of paid parental leave

Benefits For Your Future

• 401k with up to 5% matching contributions which vest 100% on day one
• Eligibility for incentive stock options

If you need an accommodation during the application or interview process, reach out to us at [e-mail] We’re here to help.

At Electra, safety is more than a policy — it’s a core value that guides every decision we make. Whether in the lab or the office, we’re committed to creating a culture where everyone takes responsibility for keeping themselves and those around them safe. Please let us know if you share our values around safety.

As set forth in Electra’s Equal Employment Opportunity policy, we do not discriminate on the basis of any protected group status under any applicable law.