What is calendar-based BMS testing really costing you?
Fixed-interval Burner Management System testing means running crews on a clock, not on evidence. Tell us where to send it, and unlock the interactive ROI calculator - a 12-year NPV model built bottom-up from your crew, rates, and test intervals.
Business Case Builder
BMS Testing Optimization
BMS Instrumentation Testing ROI Calculator
Enter your numbers below to see Burner Management System testing savings, ROI, and payback — ready to show leadership.
1. Your Inputs
Annual testing cost is always calculated bottom-up from your crew, rates, and test frequency on the Cost Builder below — no manual entry required.
Currency: USD ($)All rates, project costs, and results are in US dollars.
Burner Management Systems in scope for this business case.
BMSs
The average calendar-based interval you test on today — not all BMSs share the same prescriptive interval.
months
Interval justified once prior-use failure data supports it (from Yr 3).
months
2. Cost Builder — Build Your Annual Testing Cost
Enter your crew size, loaded rate, and field testing time. The other activities in a test cycle (planning, shop prep, permits and travel, DCS operator support, and close-out) are added per device using typical industry assumptions.
Techs assigned to each BMS test event.
techs
Fully burdened hourly cost per tech.
$/hr
Hands-on testing and restoration per device, per tech (20 devices per BMS).
hrs / device
Activity per device, per test
Basis
Person-hrs
Cost
Total per device
—
—
Person-hours per BMS test event (per device × 20 devices)—
Total cost per BMS test event—
Tests per year per BMS (=12 ÷ current interval)—
Annual cost for planned BMS testing—
3. Fixed Assumptions
Fixed model assumptions: each BMS averages 10 SIFs made up of 20 instruments to test · 12-year planning horizon · 3.5% annual inflation · 8% discount rate · data collection Yrs 1–2 · test-interval extension ramped Yrs 3–4, flat thereafter · program cost = aeShield + PSA fixed annual SaaS licenses by BMS tier + one-time implementation services (Yrs 1–2).
4. Results — Over a 12-Year Horizon (NPV)
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Total Savings, 12-Yr NPV
vs. baseline spend, net of program cost
—
ROI (Savings ÷ Baseline Spend)
Program cost alone gives a far higher return
—
Cash-Positive Year
Metric
Value
12-Year Spend Trajectory
Current (as-is) vs. optimized BMS PM budget, nominal $
Baseline (as-is)Optimized
Model Assumptions
Baseline spend escalates at 3.5%/yr inflation, uninterrupted, across the 12-year horizon.
Yrs 1–2 collect test results at the current interval (no spend change).
Starting Yr 3, prior-use failure rates justify extending the interval, ramped over 2 years (Yrs 3–4), then flat from Yr 5 on.
Annual testing cost is always built bottom-up from crew size, loaded rates, and time per test event — never entered directly.
Program cost = aeShield + Schneider Electric (PSA) SaaS licenses (fixed annual price by BMS tier, every year) + one-time aeShield and PSA services (implementation guide, PHA/LOPA and BMS templates, data migration, dashboard, event-data tag mapping, training), spread evenly over the Yrs 1–2 rollout window.
Services are priced at full cost for the first BMS; each additional BMS is priced at 25% of the first-BMS cost (template copy factor).
All spend streams are discounted to present value at an 8% discount rate; NPVs assume cash flows land at each year-end.
"Cash-positive year" is the first year in which nominal net benefit (baseline + program cost − optimized spend) turns positive.
This calculator provides a screening-level estimate for discussion purposes only. Actual savings depend on site-specific BMS counts, current test intervals, crew rates, and program execution. ROI shown is savings vs. baseline spend — program cost alone gives a far higher return.
Want a business case built around your exact site data?
We'll work through your BMS count, crew rates, and current test intervals to build a defensible number for leadership.
