Senior Controls Engineer Boulder, Colorado, United States

Electra; Boulder (CO); On-site; USD 100,000 - 175,000; Full time

Benefits offered by this job

100% paid medical, dental, vision insurance

401(k) with matching contributions

Paid parental leave

Job summary

Electra is hiring a Senior Controls Engineer in Boulder, Colorado, to design and build data acquisition and process control systems for chemical processing in the iron-making industry. The role requires at least 8 years of experience, with a focus on control systems and instrumentation while ensuring safety and compliance with industry standards.

Responsibilities include developing electrical systems, leading engineering projects, and collaborating with various teams. Exceptional candidates will have proficiencies in PLC programming, industrial automation communication protocols, and experience in chemical processing.

Qualifications

• 8+ years of industry experience in controls and data acquisition.
• 3+ years of experience with PLC programming and instrumentation.
• Strong knowledge of electrical design and industrial power distribution.

Responsibilities

• Design and maintain EIC systems for iron-production processes.
• Lead control system design and related documentation.
• Collaborate with cross-functional teams for system requirements.

Skills

PLC programming

Instrumentation

Control system design

Electrical troubleshooting

Industrial automation protocols

Tools

Siemens S7

SolidWorks Electrical

Ignition

Job description

Electra is reinventing ironmaking from the ground up with a breakthrough electrochemical technology that produces high purity, clean iron and critical co‑minerals. With two operating pilots in Boulder and a new demonstration facility underway in Jefferson County, we’re on track to reach commercial scale by the end of the decade.

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 include:

• 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 (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 multidisciplinary 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 (excluding 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.
• Proficiency with Microsoft Office suite of programs including Word, Excel, PowerPoint, Outlook, OneDrive, and SharePoint.

What we would like you to bring to the team:

• 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 $100 000‑$175 000 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:

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

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.