IIoT, SCADA & Edge Connectivity calculator

SCADA Migration Workload Calculator

Estimate SCADA migration engineering hours. Enter the count of screens or POUs (program organization units) to migrate, the engineer migration rate (objects per hour), and an allowance for FAT, SAT, validation, and cutover. The calculator returns base hours and the loaded total.

What this calculator does

  • Estimate engineering hours to migrate a SCADA project from one platform to another, from screens or POU count to migrate, the engineer migration rate (objects per hour), and an allowance for FAT, SAT, validation, and cutover.
  • Use it when an integrator or controls lead is sizing a SCADA migration sprint (legacy SCADA to Ignition, Wonderware, AVEVA, or FactoryTalk View) before quoting the project.
  • It returns the engineering hours to migrate a SCADA project to a new platform, including FAT, SAT, validation, and cutover.

Formula used

  • Base SCADA migration hours = screens or POUs ÷ engineer rate
  • Required SCADA migration hours = base hours × (1 + FAT, SAT, and cutover allowance)

Inputs explained

  • Screens or POUs to migrate: Use the count of screens, faceplates, or POUs to migrate from the legacy SCADA. Include faceplates only if they are rebuilt, not reused.
  • Engineer migration rate: Use the per-engineer rate (typical 0.5 to 2 screens per hour for production-equivalent rebuild including tag mapping and animation rebuild).
  • FAT, SAT, validation, and cutover allowance: Add the share for factory acceptance test, site acceptance test, validation (GAMP / 21 CFR Part 11 if regulated), training, and weekend cutover labor.

How to use the result

  • Use it during SCADA RFP scoping, before issuing the integrator order, or when comparing platforms for the same project.
  • It sizes labor only. Pair with the SCADA upgrade cost calculator for platform cost and the tag mapping workload for the tag side of the migration.

Common questions

  • What is a realistic per-engineer rate? 0.5 to 2 screens per hour for production-equivalent rebuild including tag remap and animation. Below 0.5 usually means the legacy project is poorly documented.
  • Why such a high FAT-SAT allowance? Validated industries (life sciences, food, regulated chemicals) easily run 60 to 100 percent allowance because of FAT, SAT, IQ, OQ, PQ, and weekend cutover. Non-regulated plants run 25 to 40 percent.
  • Do I include alarm rationalization? No. Use the alarm rationalization workload calculator for that work. Many migrations bundle it; size it separately for clarity.
  • How do I model parallel engineers? Run hours and divide by parallel engineer count for calendar duration. Hours is what gets billed.

Last reviewed 2026-05-12.