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ABB Control System Specialist (m/f/d)
For a project in the power plant environment, we are urgently looking for a freelance specialist for the migration and customization of the ABB 800xA control system.
- Typical tasks in this role:**
- Implementation of programming and commissioning with the ABB 800xA distributed control system.
- Migration of existing control system logic to the new system version, including adjustment of controllers and I/O modules.
- Creation and adjustment of process graphics, operator interfaces, and alarm management configurations.
- Performing system tests, error analyses, and performance optimizations to ensure plant availability and controllability.
- Technical support for operations 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 (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 testing and development environments.
- Databases: SQL knowledge for analyzing 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 system components/functions migrated per week/month.
- System availability: control system uptime after migration > 99.9%.
- Error rate during commissioning: 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 a 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).
- Managing 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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ABB Control System Specialist (m/f/d)
Industry
Energy
Areas
Information Technology (IT)
Project Management
Project info
- Period06.10.2025 - 06.01.2026
- 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 looking for a freelance specialist for the migration and customization of the ABB 800xA control system.
Typical tasks in this role:**
Implementation of programming and commissioning with the ABB 800xA distributed control system.
Migration of existing control system logic to the new system version, including adjustment of controllers and I/O modules.
Creation and adjustment of process graphics, operator interfaces, and alarm management configurations.
Performing system tests, error analyses, and performance optimizations to ensure plant availability and controllability.
Technical support for operations 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 (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 testing and development environments.
Databases: SQL knowledge for analyzing 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 system components/functions migrated per week/month.
System availability: control system uptime after migration > 99.9%.
Error rate during commissioning: 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 a 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).
Managing 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 comparable 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 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 attributes 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 working style.
English
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