Senior Controls Engineer Boulder, Colorado

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.

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.

• 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 Solid Works 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.

• 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, One Drive, and SharePoint.

• Proficiency with…