Senior Controls Engineer

Electra-posted 9 days ago

$105,000 - $140,000/Yr

Full-time • Mid Level

Boulder, CO

101-250 employees

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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. 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 (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

Bachelor’s degree in electrical engineering, control systems engineering, automation engineering, or related
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.
High level programming experience in C/C++/C#, Python, Javascript, or equivalent
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

Master’s degree in electrical engineering, control systems engineering, automation engineering, or related
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

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)
100% paid premiums across all medical, dental, vision, and telemedicine plans
12 weeks of paid parental leave
401k with up to 5% matching contributions which vest 100% on day one
Eligibility for incentive stock options

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