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ABB control system specialist (m/f/d)

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Industry
Energy
Areas
Information Technology (IT)
Project Management

Project info

  • Period
    21.07.2025 - 21.10.2025
  • Capacity
    from 90%
  • Daily rate
    720 - 970€
  • Location
    Berlin, Germany
  • Language
    • German
      (Native)
  • Remote
    up 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.

  • Performing system tests, error analysis and performance optimizations to ensure plant availability and controllability.

  • Technical support for operational staff during commissioning and ramp-up phases.

  • Creation and maintenance of technical documentation (functional diagrams, configuration descriptions, test protocols).

  • Close collaboration 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: Knowledge of SQL for analyzing historical data (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 operational staff on the new system environment.

  • Special challenges, risks or specifics:**

  • Migration during ongoing 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 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 operational 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 a 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.

  • Familiarity with primary and secondary power plant control.

  • Personal qualities and mindset:**

  • Strong analytical and systematic problem-solving skills.

  • High reliability and a pronounced sense of responsibility and safety.

  • 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.