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 the migration and adaptation of the ABB 800xA control system is urgently sought.
- 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 adaptation of process displays, operator interfaces, and alarm management configurations.
- Execution of system tests, error analysis, and performance optimizations to ensure plant availability and controllability.
- Technical support for operations personnel during the commissioning and ramp-up phase.
- Preparation 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 (including AC 800M controller, Information Management, Batch Control).
- Engineering tools: Control Builder M, Process Graphics Migration Tool, Bulk Data Manager.
- Fieldbus systems: PROFIBUS, Foundation Fieldbus, Modbus.
- Virtualization: VMware, Hyper-V for test and development environments.
- Databases: SQL knowledge for analysis of historical data (e.g. 800xA History).
- Knowledge of relevant standards for process and power plant technology (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 operations personnel on the new system environment.
- Specific challenges, risks or peculiarities:**
- Migration during live 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 displays 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 personnel.
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The system is already rolled out at one site and is now to be further scaled.
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The engineer will evaluate faults, propose solutions, and defend the client's position when necessary.
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.
- 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.
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- Represent and communicate problems clearly to relevant stakeholders.
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ABB Control System Specialist (m/f/d)
Industry
Energy
Areas
Information Technology (IT)
Project Management
Project info
- Period02.07.2025 - 02.10.2025
- 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 the migration and adaptation of the ABB 800xA control system is urgently sought.
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 adaptation of process displays, operator interfaces, and alarm management configurations.
Execution of system tests, error analysis, and performance optimizations to ensure plant availability and controllability.
Technical support for operations personnel during the commissioning and ramp-up phase.
Preparation 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 (including AC 800M controller, Information Management, Batch Control).
Engineering tools: Control Builder M, Process Graphics Migration Tool, Bulk Data Manager.
Fieldbus systems: PROFIBUS, Foundation Fieldbus, Modbus.
Virtualization: VMware, Hyper-V for test and development environments.
Databases: SQL knowledge for analysis of historical data (e.g. 800xA History).
Knowledge of relevant standards for process and power plant technology (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 operations personnel on the new system environment.
Specific challenges, risks or peculiarities:**
Migration during live 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 displays 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 personnel.
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.
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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