BARNSLEY'S hopes of repeating their celebrated FA Cup win over Chelsea in 2008 were scuppered by Tammy Abraham.
The England striker scored the only goal of the fifth-round tie at chilly Oakwell in the 64th-minute, then denied the Reds what would have been a deserved equaliser when he cleared off the line from substitute Michael Sollbauer 14 minutes from the end.
Chelsea, FA Cup winners in 2018 and three times finalists in the last four seasons, will now host Sheffield United, having been made to work hard for their quarter-final berth by Valerien Ismael's battlers.
While Barnsley made just one change from the side which drew at Nottingham Forest in the Championship last time out - Victor Adeboyejo for Dominik Frieser - Chelsea manager Thomas Tuchel retained just one player, Andreas Christensen, from the starting side which won at Sheffield United in the Premier League.
But the Londoners still had a dazzling array of talent on display in their second visit to South Yorkshire in five days, including the world's most expensive goalkeeper Kepa, a £72million buy from Athletic Bilbao who has struggled to dislodge usual first choice Edouard Mendy, and top scorer Abraham, who now has 11 this season.
The Blues striker was aiming to get one over on Reds keeper Brad Collins, a teammate in the Chelsea side which claimed the UEFA Youth League title in 2016.
It was the third meeting of these clubs in the FA Cup, and perhaps surprisingly, Barnsley had won both previous ties without conceding a goal, although they were beaten 6-0 by Chelsea at Stamford Bridge in the third round of the Carabao (League) Cup in September.
Collins kept goal that night, when Abraham scored once, but kept clean sheets in both of Barnsley's previous FA Cup ties this season, against Tranmere Rovers and Norwich City.
Chelsea were pinned in their own half for the first five minutes as Barnsley made an energetic start without actually troubling Kepa.
That changed in the tenth minute, when the Spanish international had to react smartly to thwart Callum Brittain at close quarters after he shrugged off Marcos Alonso to meet an Alex Mowatt cross with a shot.
Chelsea slowly got into the game, and Collins had to backpedal to catch after Toby Sibbick challenged Abraham and the ball looped up into the air.
Soon after, Abraham's penalty claims as he took a tumble when Sibbick challenged him were waved away by referee Martin Atkinson.
Another Abraham appeal, this time after a tackle by Mads Andersen, was rejected after 23 minutes.
Callum Hudson-Odoi broke free down the Chelsea right on 40 minutes and Christian Pulicic met his deep cross but couldn't get his shot on target.
Barnsley came close again from a corner a minute before the break, with Adeboyejo agonisingly close to touching in Conor Chaplin's low drive across goal.
Barnsley's impressive first-half display seemed to have given Tuchel some food for thought, because his side started the second half with Reece James and Antonio Rudiger on in place of Alonso and Christensen.
The home side made a double change of their own on 58 minutes, when Chaplin and Adeboyejo made way for Frieser and new American loan signing Daryl Dike, who was making his Barnsley debut.
Chelsea were looking sharper this half, and after Callum Hudson-Odoi weaved his way into the area and shot narrowly wide and Rudiger headed just off target from Hakim Ziyech's delivery, Abraham opened the scoring after 64 minutes, tapping home from close range from Reece James' pass.
There was a hint of offside, but with VAR not in use in this tie, referee Atkinson's decision stood unchallenged, just as it had done for Abraham's penalty claims.
Ziyech was replaced by teenager Tino Anjorin after 68 minutes, while Barnsley soon made three more changes, Jordan Williams and Romal Palmer replacing Brittain and Herbie Kane on 72 minutes and Sollbauer coming on for Sibbick after 75.
Sollbauer almost made an instant impact when he hooked a Mowatt free-kick goalwards, but the effort was headed off the line by the busy Abraham.
Barnsley: Collins, Sibbick (Sollbauer, 75), Helik, Andersen, Brittain (J Williams, 72), Kane (Palmer, 72), Mowatt, Styles, Adeboyejo (Frieser, 58), Woodrow, Chaplin (Dike, 58). Subs not used: Moon, Oduor, Thompson, Walton.
Chelsea: Kepa, Emerson, Christensen (Rudiger, HT), Zouma, Alonso (James, HT), Gilmour, Kante, Hudson-Odoi, Ziyech (Anjorin, 68), Pulisic (Kovacic, 80), Abraham. Subs not used: Chilwell, Azpilicueta, Bate, Giroud, Caballero.
Referee Martin Atkinson (West Yorkshire).
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