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For a project in the power plant environment, a freelance specialist is urgently needed for the migration and adaptation of the ABB 800xA control system.
- Typical tasks in this role:**
- Implementation of programming and commissioning with the ABB 800xA process control system.
- Migration of existing control system logic to the new system version, including adaptation of controllers and I/O modules.
- Creation and adjustment of process graphics, user interfaces and alarm management configurations.
- Conducting system tests, error analyses and performance optimizations to ensure plant availability and controllability.
- Technical support of operating personnel during commissioning and ramp-up phases.
- Creation and maintenance of technical documentation (functional diagrams, configuration descriptions, test protocols).
- Close collaboration with the process engineering, electrical engineering departments and the plant operator.
- Relevant technologies, tools or methods:**
- Control system: ABB Ability™ System 800xA (incl. AC 800M controller, Information Management, Batch Control).
- Engineering tools: Control Builder M, Process Graphics Migration Tool, Bulk Data Manager.
- Fieldbuses: PROFIBUS, Foundation Fieldbus, Modbus.
- Virtualization: VMware, Hyper-V for test and development environments.
- Databases: Knowledge of SQL for historical data analysis (e.g. 800xA History).
- Familiarity with relevant standards for process and power plant engineering (e.g. IEC 61508, IEC 61511).
- Typical KPIs or success metrics:**
- Migration speed: number of migrated system components/functions per week/month.
- System availability: control system uptime after migration > 99.9%.
- Commissioning error rate: number of critical software bugs after go-live < 5.
- Test coverage: percentage of successfully executed and documented test cases > 95%.
- Adherence to project schedule: completion of migration and commissioning by the defined deadline.
- Operator acceptance: positive feedback from operating personnel on the new system environment.
- Specific challenges, risks or particulars:**
- Migration during operation (“brownfield”) with minimal downtime.
- Ensuring compatibility between old and new system components (hardware/software).
- High complexity of process logic in power plants (e.g. boiler control, turbine regulation).
- Risk of cyber-security vulnerabilities in networked control systems (e.g. CVEs for 800xA).
- Management of interfaces to third-party systems (e.g. MES, ERP).
- Need for intensive and precise cooperation between control technology, process engineering and operations.
- Concrete deliverables:**
- Migrated and operational control logic on the target system.
- Fully tested and customer-approved process graphics and user interfaces.
- Acceptance protocols for Factory Acceptance Test (FAT) and Site Acceptance Test (SAT).
- Updated technical plant documentation.
- Final migration report with lessons learned.
- Trained operating personnel.
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ABB Control System Specialist (m/f/d)
Industry
Energy
Areas
Information Technology (IT)
Project Management
Project info
- Period11.08.2025 - 11.11.2025
- Capacityfrom 90%
- Daily rate720 - 970€
- LocationBerlin, Germany
- Language
- German(Native)
- German
- Remoteup to 10%
Description
For a project in the power plant environment, a freelance specialist is urgently needed for the migration and adaptation of the ABB 800xA control system.
Typical tasks in this role:**
Implementation of programming and commissioning with the ABB 800xA process control system.
Migration of existing control system logic to the new system version, including adaptation of controllers and I/O modules.
Creation and adjustment of process graphics, user interfaces and alarm management configurations.
Conducting system tests, error analyses and performance optimizations to ensure plant availability and controllability.
Technical support of operating personnel during commissioning and ramp-up phases.
Creation and maintenance of technical documentation (functional diagrams, configuration descriptions, test protocols).
Close collaboration with the process engineering, electrical engineering departments and the plant operator.
Relevant technologies, tools or methods:**
Control system: ABB Ability™ System 800xA (incl. AC 800M controller, Information Management, Batch Control).
Engineering tools: Control Builder M, Process Graphics Migration Tool, Bulk Data Manager.
Fieldbuses: PROFIBUS, Foundation Fieldbus, Modbus.
Virtualization: VMware, Hyper-V for test and development environments.
Databases: Knowledge of SQL for historical data analysis (e.g. 800xA History).
Familiarity with relevant standards for process and power plant engineering (e.g. IEC 61508, IEC 61511).
Typical KPIs or success metrics:**
Migration speed: number of migrated system components/functions per week/month.
System availability: control system uptime after migration > 99.9%.
Commissioning error rate: number of critical software bugs after go-live < 5.
Test coverage: percentage of successfully executed and documented test cases > 95%.
Adherence to project schedule: completion of migration and commissioning by the defined deadline.
Operator acceptance: positive feedback from operating personnel on the new system environment.
Specific challenges, risks or particulars:**
Migration during operation (“brownfield”) with minimal downtime.
Ensuring compatibility between old and new system components (hardware/software).
High complexity of process logic in power plants (e.g. boiler control, turbine regulation).
Risk of cyber-security vulnerabilities in networked control systems (e.g. CVEs for 800xA).
Management of interfaces to third-party systems (e.g. MES, ERP).
Need for intensive and precise cooperation between control technology, process engineering and operations.
Concrete deliverables:**
Migrated and operational control logic on the target system.
Fully tested and customer-approved process graphics and user interfaces.
Acceptance protocols for Factory Acceptance Test (FAT) and Site Acceptance Test (SAT).
Updated technical plant documentation.
Final migration report with lessons learned.
Trained operating personnel.
Requirements
Must-haves:**
Degree in automation, electrical or control engineering or an equivalent qualification as a technician with many years of experience.
Several years of in-depth project experience with the ABB 800xA control system, ideally in the power plant environment.
Proven experience in programming, visualization and commissioning of process control systems.
Experience in carrying out system migrations.
Willingness to work on-site in an industrial plant.
Nice-to-haves:**
ABB certifications for System 800xA (e.g. Certified Engineer).
Knowledge of functional safety (SIL).
Experience with virtualization technologies and network engineering.
Knowledge of secondary and primary control of power plants.
Personal traits and mindset:**
Strong analytical and systematic problem-solving skills.
High reliability and strong sense of responsibility and safety awareness.
Good communication and team skills for working in interdisciplinary project teams.
Resilience and flexibility, especially during critical commissioning phases.
Independent and structured way of working.
English
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