Bailey INFI90 Reverse Engineering Consulting
Even with minimal or outdated documentation, we provide a full, accurate picture of your Bailey INFI90 system (INFI 90, OIS, operator stations, and control modules) through our structured consulting process.
Our Step-by-Step Consulting Process
- Full system backup (INFI 90 nodes, OIS, control modules, and point database)
- Document all INFI 90 hardware, communication links, and I/O mappings
- Extract and catalog control logic blocks and configuration files
- Create cross-reference reports for every point and logic block
- Build plain-English functional specification for each major process area
- Map legacy points and blocks to modern descriptive tags and data structures
- Develop phased migration roadmap and cutover guidance
Bailey INFI90 Reverse Engineering & Migration Checklist
| Phase | Item | Description |
|---|---|---|
| 1. Preparation | Full backup | INFI 90 nodes, OIS, control modules, point database |
| 2. Hardware | Node & module inventory | INFI 90 hardware, communication links, I/O mappings |
| 3. Logic | Control block extraction | All logic blocks and configuration files |
| 4. Points | Point database mapping | Every point → modern tag name & scaling |
| 5. Functional Spec | Plain English | Cause & effect for every major process area |
| 6. Tag Database | Modern tags | Descriptive tags, alarms, engineering units |
| 7. Migration Plan | Phased cutover | Hot cutover or parallel operation strategy |
Large, complex DCS? A sectional hot cutover keeps the plant running through migration.
Where ROI saves you money on your Bailey INFI 90 migration
A modern migration already keeps your existing field I/O and wiring — that is the right approach. So the savings are not mechanical, they are commercial: the vendor still scopes and prices the migration to maximize their sale. With more than 25 years on the vendor side, we make sure you do not overpay for the migration you are already going to do.
Right-size the scope
Trim padded engineering, over-specified software, and licenses you won’t use — while keeping the redundant controllers and I/O that protect uptime.
Negotiate the commercial deal
Insider knowledge of how vendors price migrations: list-to-net discounts, and license and support terms.
Cut the lifecycle / service agreement
A typical agreement runs about 10% to 15% of the DCS system value per year; we renegotiate it lower — recurring savings for years, not a one-time win.
Level competing vendor bids
Several vendors quoting the same job? We normalize every bid to one scope for a true comparison, expose the padding and change-order traps, and use the competition to cut your price.
Phase to your budget & turnarounds
Remove the vendor’s end-of-life deadline leverage; defer non-critical scope to later capital cycles.
Owner’s representative through delivery
Review proposals, FAT / SAT, and control the change orders and overruns where migrations quietly bleed.
On an average 10,000 I/O migration: roughly 20–25% off the project cost, plus about $70–90K per year off the lifecycle agreement — and ROI’s fee is a fraction of what it saves you.
Illustrative · anchored to your actual vendor proposalWant the full breakdown? Download the DCS Migration Savings one-pager (PDF) →