Project details
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ABB Control System Specialist (m/f/d)
For a project in the power plant environment, a freelance specialist for migrating and adapting the ABB 800xA control system is needed at short notice.
- 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, operator interfaces and alarm management configurations.
- Execution of system tests, error analysis and performance optimizations to ensure plant availability and controllability.
- Technical support of operations staff during the commissioning and ramp-up phase.
- Preparation and maintenance of technical documentation (functional diagrams, configuration descriptions, test protocols).
- Close cooperation with the process engineering, electrical engineering departments 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 knowledge for historical data analysis (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 defined deadline.
- Operator acceptance: positive feedback from operations staff on the new system environment.
- Key challenges, risks or specifics:**
- Migration in running 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 cybersecurity 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 collaboration between control engineering, process engineering and operations.
- Concrete deliverables:**
- Migrated and operational control logic on the target system.
- Fully tested and customer-approved process graphics and operator 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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The system is already rolled out at one site and now needs to be scaled further.
The role includes supporting the introduction of new features or versions of the system, implementing system customizations and optimizations based on production requirements, and assisting with the rollout. The consultant will work closely with internal teams and external service providers to ensure quick identification and resolution of issues in the MES system.
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- Implement system customizations and optimizations based on production requirements
- Assist with the rollout to additional sites
- Quickly identify and resolve issues in the MES system
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- Review and navigate complex documentation related to electrical systems.
- Identify and resolve design and installation issues, especially from third-party packages.
- Handle MCCs, generic point lists, and interface mismatches.
- Evaluate responsibility for faults:
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Electrical Commissioning Engineer (m/f/d)
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Clear communication with stakeholders and independent client-side representation are key aspects of this role.
- Act as the first point of contact on-site for electrical commissioning issues.
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- Identify and resolve design and installation issues, especially from third-party packages.
- Handle MCCs, generic point lists, and interface mismatches.
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- Represent and communicate problems clearly to relevant stakeholders.
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A company is looking for a specialist Construction Manager for Electrical Engineering and a specialist Construction Manager for Process Control (Siemens T3000) for a challenging project. The goal of the project is the technical monitoring and control of the process control interfaces of the existing plant during the integration of the new system, as well as ensuring quality and contractual compliance during the construction and commissioning phase.
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Frontend developer to HR platform with Angular experience
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ABB Control System Specialist (m/f/d)
Industry
Energy
Areas
Information Technology (IT)
Project Management
Project info
- Period07.07.2025 - 07.10.2025
- 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 for migrating and adapting the ABB 800xA control system is needed at short notice.
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, operator interfaces and alarm management configurations.
Execution of system tests, error analysis and performance optimizations to ensure plant availability and controllability.
Technical support of operations staff during the commissioning and ramp-up phase.
Preparation and maintenance of technical documentation (functional diagrams, configuration descriptions, test protocols).
Close cooperation with the process engineering, electrical engineering departments 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 knowledge for historical data analysis (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 defined deadline.
Operator acceptance: positive feedback from operations staff on the new system environment.
Key challenges, risks or specifics:**
Migration in running 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 cybersecurity 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 collaboration between control engineering, process engineering and operations.
Concrete deliverables:**
Migrated and operational control logic on the target system.
Fully tested and customer-approved process graphics and operator 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 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 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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