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ABB Control System Specialist (m/f/d)
For a project in the power plant environment, we are urgently seeking a freelance specialist for the migration and adaptation of the ABB 800xA control system.
- Typical responsibilities in this role:**
- Implement programming and commissioning with the ABB 800xA process control system.
- Migrate existing control system logic to the new version, including adjustments to controllers and I/O modules.
- Create and adapt process graphics, user interfaces, and alarm management configurations.
- Conduct system tests, troubleshoot issues, and optimize performance to ensure plant availability and control capability.
- Provide technical support to operations staff during commissioning and ramp-up phases.
- Prepare and maintain technical documentation (functional diagrams, configuration descriptions, test protocols).
- Collaborate closely with process engineering, electrical engineering, and the plant operator.
- Relevant technologies, tools or methods:**
- Control system: ABB Ability™ System 800xA (including 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: SQL skills for analyzing historical data (e.g. 800xA History).
- Knowledge of relevant standards for process and power plant engineering (e.g. IEC 61508, IEC 61511).
- Typical KPIs or success metrics:**
- Migration speed: number of system components/functions migrated 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 agreed deadline.
- Operator acceptance: positive feedback from operations staff on the new system environment.
- Key challenges, risks or specifics:**
- Migration in a live environment (“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 cybersecurity vulnerabilities in networked control systems (e.g. CVEs for 800xA).
- Managing interfaces to third-party systems (e.g. MES, ERP).
- Requirement for close and precise collaboration between control engineering, process engineering and operations.
- Concrete deliverables:**
- Migrated and operational control logic on the target system.
- Fully tested and client-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 operations staff.
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ABB Control System Specialist (m/f/d)
Industry
Energy
Areas
Information Technology (IT)
Project Management
Project info
- Period29.09.2025 - 30.12.2025
- Capacityfrom 90%
- Daily rate720 - 970€
- LocationBerlin, Germany
- Language
- German(Native)
- German
- Remoteup to 10%
Description
For a project in the power plant environment, we are urgently seeking a freelance specialist for the migration and adaptation of the ABB 800xA control system.
Typical responsibilities in this role:**
Implement programming and commissioning with the ABB 800xA process control system.
Migrate existing control system logic to the new version, including adjustments to controllers and I/O modules.
Create and adapt process graphics, user interfaces, and alarm management configurations.
Conduct system tests, troubleshoot issues, and optimize performance to ensure plant availability and control capability.
Provide technical support to operations staff during commissioning and ramp-up phases.
Prepare and maintain technical documentation (functional diagrams, configuration descriptions, test protocols).
Collaborate closely with process engineering, electrical engineering, and the plant operator.
Relevant technologies, tools or methods:**
Control system: ABB Ability™ System 800xA (including 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: SQL skills for analyzing historical data (e.g. 800xA History).
Knowledge of relevant standards for process and power plant engineering (e.g. IEC 61508, IEC 61511).
Typical KPIs or success metrics:**
Migration speed: number of system components/functions migrated 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 agreed deadline.
Operator acceptance: positive feedback from operations staff on the new system environment.
Key challenges, risks or specifics:**
Migration in a live environment (“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 cybersecurity vulnerabilities in networked control systems (e.g. CVEs for 800xA).
Managing interfaces to third-party systems (e.g. MES, ERP).
Requirement for close and precise collaboration between control engineering, process engineering and operations.
Concrete deliverables:**
Migrated and operational control logic on the target system.
Fully tested and client-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 operations staff.
Requirements
Must-haves:**
Degree in automation, electrical or control engineering, or equivalent qualification as a technician with many years of experience.
Several years of in-depth project experience with ABB 800xA, ideally in the power plant sector.
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 facility.
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 in power plants.
Personal qualities and mindset:**
Strong analytical and systematic problem-solving skills.
High reliability and a strong sense of responsibility and safety awareness.
Good communication and teamwork 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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