Introduction

For decades, ABB Bailey INFI 90 has been a cornerstone of distributed control systems (DCS) in industries such as power generation, oil and gas, chemicals, and pulp and paper.

Many of these systems continue to operate reliably today, controlling critical processes with high availability and proven stability.

However, as industrial digitalization accelerates, end users face increasing pressure to integrate legacy control platforms with modern architectures that offer advanced visualization, analytics, and lifecycle support.

ABB System 800xA represents ABB’s flagship automation platform, combining control, safety, electrical, and information management within a single environment.

Rather than forcing a disruptive rip-and-replace strategy, ABB positions Bailey INFI 90 modules as a practical bridge—allowing plants to protect existing investments while gradually migrating toward System 800xA.

The Ongoing Value of Bailey INFI 90

Introduced in the late 1980s, the INFI 90 system was designed with modularity and redundancy at its core. Many installations have now been in service for 25–35 years, yet remain operational due to robust hardware design and conservative lifecycle management.

Key strengths of INFI 90 include:

· Deterministic control performance suitable for continuous processes

· Proven redundancy concepts for power supplies, communication, and controllers

· A large installed base across heavy industries

· Long-term familiarity among operations and maintenance teams

According to industry lifecycle studies, more than 60% of legacy DCS systems worldwide are still actively controlling processes beyond their original design life.

This makes coexistence and staged modernization a practical necessity rather than a theoretical option.

Why Migrate Toward System 800xA?

System 800xA is not just a DCS upgrade; it is an integrated automation platform. ABB positions it as an “Extended Automation” system that unifies control and information across domains.

Key capabilities include:

· Unified HMI for process, electrical, and safety systems

· Native support for advanced analytics and asset health monitoring

· Scalable architecture from small process units to enterprise-wide deployments

· Modern cybersecurity concepts aligned with IEC 62443 standards

From a performance perspective, ABB reports that plants adopting System 800xA can reduce engineering effort by up to 30% during expansions and cut operator response time by 20–40% through improved situational awareness.

INFI 90 as a Migration Bridge

Rather than abandoning INFI 90 assets, ABB enables them to function as an interoperable layer within a System 800xA environment. This approach minimizes risk and downtime while extending the useful life of installed hardware.

Common bridging strategies include:

1.Controller Coexistence
INFI 90 controllers continue executing control logic, while System 800xA handles visualization and higher-level functions.

2.Communication Gateways
Interface modules and communication adapters allow INFI 90 networks to exchange data with 800xA controllers and operator stations.

3.Phased Replacement
Individual INFI 90 modules or controllers can be replaced step by step, without halting the entire process.

This staged approach aligns with industry migration best practices, where over 70% of modernization projects are executed incrementally to avoid production losses.

Typical INFI 90 Modules in Migration Projects

The following table highlights representative INFI 90 module categories commonly retained or integrated during System 800xA migration projects:

By maintaining these modules, plants can avoid large-scale rewiring, which often accounts for 40–50% of total migration costs in full replacement projects.

Operational and Economic Benefits

Using INFI 90 modules as a bridge delivers tangible benefits:

· Reduced capital expenditure: Avoids immediate full-system replacement

· Lower downtime risk: Migration can occur during planned maintenance windows

· Faster operator adoption: Gradual transition to modern HMIs

· Extended asset lifecycle: Proven hardware remains productive

From a financial perspective, ABB case studies indicate that phased migrations can reduce total modernization costs by 25–35% compared to complete system overhauls.

Lifecycle Support and Spare Parts Considerations

One challenge facing legacy systems is long-term spare parts availability. While ABB has phased out manufacturing for many INFI 90 components, demand remains strong due to the large installed base.

Independent automation suppliers play a critical role by providing:

· New and professionally tested legacy modules

· Obsolete or discontinued INFI 90 spare parts

· Rapid global logistics to minimize downtime

Ensuring access to reliable spare parts is essential for plants operating hybrid INFI 90 and System 800xA environments.

Conclusion

ABB Bailey INFI 90 modules continue to serve as a strategic bridge between legacy process control and modern automation platforms.

By integrating INFI 90 systems with ABB System 800xA, industrial operators gain access to advanced visualization, analytics, and lifecycle tools—without sacrificing the stability of proven control hardware.

This migration path balances innovation with operational continuity, making it particularly attractive for asset-intensive industries where uptime, safety, and cost control remain paramount.

For organizations planning long-term digital transformation, INFI 90 is not an obstacle—it is a foundation.

Official Contact Information

Apter Power
Sales Manager: May
E-mail: sales8@apterpower.com

For inquiries regarding ABB Bailey INFI 90 modules, System 800xA integration, or spare parts support, please contact the official representative above.