News

ABB has introduced Automation Extended, a comprehensive program designed to help industrial facilities modernize their distributed control systems (DCS) without disruption to ongoing operations. The program, announced on November 1, 2026, addresses a critical challenge facing process industries worldwide: aging control infrastructure that requires upgrades but cannot afford extended shutdowns.

The Automation Extended program builds on ABB's proven Ability System 800xA platform, enabling phased migration from legacy systems to modern distributed control systems. This approach allows plants to maintain production continuity while gradually implementing advanced automation capabilities. The program is particularly relevant for facilities operating ABB's older Advant OCS, MasterPiece, and INF 90 systems, which have supported operations for decades but now face obsolescence risks.

"Industrial facilities cannot afford unplanned downtime during control system upgrades," said Marcus Lindh, President of ABB's Process Automation business. "Automation Extended provides a structured pathway to modernization that preserves operational continuity while unlocking the benefits of digital transformation."

The program addresses several key pain points in DCS modernization. First, it eliminates the need for "big bang" replacements that require months of shutdown. Instead, facilities can migrate in phases, typically over 18 to 36 months, with each phase carefully planned to minimize operational impact. Second, the program ensures compatibility between legacy field instruments and modern controllers, protecting existing investments in process instrumentation.

ABB's approach leverages virtualization technology to run legacy control strategies on modern hardware. This means that existing control logic, operator interfaces, and historical data can be preserved during migration, reducing revalidation costs and operator retraining requirements. The program also includes comprehensive cybersecurity enhancements, addressing growing concerns about industrial network vulnerabilities.

The process automation market has seen increasing demand for modernization solutions as facilities face multiple pressures. Regulatory requirements for improved safety and environmental compliance necessitate advanced control capabilities. Workforce shortages make it difficult to find engineers familiar with legacy systems. Meanwhile, the push for energy efficiency and sustainability requires more sophisticated process optimization tools.

Automation Extended includes several service components. ABB conducts detailed control system assessments to identify migration priorities and develop customized implementation plans. The company provides remote monitoring capabilities through its Ability Collaborative Operations service, enabling proactive support during and after migration. Training programs ensure that maintenance teams and operators can effectively manage the modernized systems.

The program's modular architecture allows facilities to prioritize upgrades based on operational needs and budget constraints. Some plants may focus first on safety instrumented systems to meet updated functional safety standards. Others may prioritize advanced process control applications to improve product quality or reduce energy consumption. The flexibility of the approach ensures that each facility can achieve its specific objectives.

ABB has already deployed Automation Extended at several customer sites. A European refinery successfully migrated from a 20-year-old INF 90 system to System 800xA over a 24-month period, completing the project without a single day of unplanned downtime. The modernization enabled the refinery to implement advanced process control strategies that improved energy efficiency by 3.2 percent.

The program also addresses the growing importance of industrial connectivity. Modern DCS platforms must integrate with enterprise resource planning systems, supply chain management tools, and cloud-based analytics platforms. Automation Extended includes pre-configured interfaces for common enterprise systems, reducing integration complexity and implementation time.

ABB's competitors have introduced similar modernization programs, but ABB's approach differentiates itself through the breadth of its installed base and the depth of its industry expertise. The company has over 30,000 DCS systems installed worldwide, providing extensive reference libraries and best practices for various process industries.

The DCS market is projected to grow at a compound annual growth rate of 6.8 percent through 2028, according to ARC Advisory Group. Much of this growth will come from modernization projects rather than greenfield installations, as facilities seek to extend the life of existing assets while gaining access to digital capabilities.

Automation Extended pricing varies based on system size and complexity, but ABB emphasizes the total cost of ownership benefits. By avoiding extended shutdowns, facilities can maintain revenue generation during migration. The improved efficiency and reliability of modern systems typically deliver payback within two to three years of completion.

The program includes options for cloud connectivity, enabling facilities to leverage ABB's Ability Edge and cloud platforms for predictive maintenance, performance monitoring, and collaborative operations. This connectivity supports the growing trend toward data-driven decision making in process industries.

ABB's announcement comes at a time when the process automation industry is experiencing strong demand. The company reported Q3 2026 orders growth of 11 percent, with particularly strong performance in the process automation segment. The Automation Extended program is expected to further accelerate this growth by addressing the large installed base of aging control systems.