IIoT, SCADA & Edge Connectivity worked example

Sensor Battery Replacement Load at 29% cmms, disposal, and lockout allowance: a worked example

This worked example runs the sensor battery replacement load numbers for a tougher week than the baseline: 29% cmms, disposal, and lockout allowance instead of the typical 40%. Estimate annual technician hours to replace wireless sensor batteries from the count of batteries due, technician replacement rate (batteries per hour with travel), and an allowance for CMMS closeout, disposal, and lockout.

The inputs for this scenario

  • Batteries due for replacement in the year: 320 batteries (held at the documented default)
  • Technician replacement rate: 8 batteries / hr (held at the documented default)
  • CMMS, disposal, and lockout allowance: 29 % (the input this scenario stresses; the baseline uses 40)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base battery replacement hours = batteries due รท technician rate.
  • Required battery replacement hours works out to 51.6 hr at these inputs, and this is the headline figure for the scenario.
  • Base battery replacement hours works out to 40 hr at these inputs.
  • CMMS, disposal, and lockout allowance works out to 29 % at these inputs.
  • Technician replacement rate works out to 8 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where cmms, disposal, and lockout allowance sits at 40% and the headline result is 56 hr, this scenario comes in 7.86% below the baseline at 51.6 hr.
  • Use it during annual maintenance planning or when evaluating the true labor cost of a wireless sensor or condition-monitoring deployment. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required battery replacement hours: 51.6 hr (headline result)
  • Base battery replacement hours: 40 hr
  • CMMS, disposal, and lockout allowance: 29 %
  • Technician replacement rate: 8 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Sensor Battery Replacement Load calculator, set cmms, disposal, and lockout allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.