Safety Lifecycle Management

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.

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aeShield 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.
Changes the symbol shown throughout — no FX conversion applied.
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

Build up your annual testing cost from crew, time, and rates. This is the sole, bottom-up source for the ROI Calculator — no shortcuts.
Crew & loaded rates
# of instrument techs on crew
techs
Instrument tech loaded rate
$ /hr
DCS operator loaded rate
$ /hr
Time per test event (hours)
Shop prep (per tech)
hrs
Field testing (per tech)
hrs
Return-to-shop paperwork (per tech)
hrs
hrs
Tech-hours per test event (all techs, all phases)—
Total cost per BMS test event—
Tests per year per BMS (=12 ÷ current interval)—
Annual cost for planned BMS testing—

3. Fixed & Advanced Assumptions

Drives program-cost scaling (SaaS/setup fees), normalized to a 20,000-instrument reference program.
instr / BMS
Safety Instrumented Functions per BMS — informational, shown in the assumptions summary.
SIFs / BMS
Fixed model assumptions: 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 = SaaS/platform fee + one-time setup, data-migration, and rollout fee (Yrs 1–2).

4. Results — Over a 12-Year Horizon (NPV)

—
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 = SaaS/platform fee (recurring, inflated annually) + one-time setup / data-migration / rollout fee (Yrs 1–2 data-collection window).
  • Program cost basis scales linearly with total instruments (# of BMSs × instruments/BMS), normalized to a 20,000-instrument reference program.
  • 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.

Talk to our team →
aeShield  |  Digital Safety Lifecycle Management
aeshield.com  |  mike.scott@aeshield.com  |  greg.swinson@aeshield.com  |  Greenville, SC