15.Cpt 8 Cost Estimation

Study on Rural Energy Supply with Utilization of Renewable Energy
in Rural Areas in the Republic of Indonesia
CHAPTER 8
Manual for Micro-hydro power Development

Chapter 8
COST ESTIMATION
8.1 Cost Estimation for Rough Planning Stage

When you are going to make a trial calculation of construction cost in Rough
Planning Stage, it can be calculated by the method shown in Table8.1.2. However,
before calculating, it is necessary to carry out an easy field survey, and decide the item
mentioned to Table8.1.1.
Table8.1.1 Items to make a trial calculation of construction cost
Description
Item
Plan
Maximum Out Put (kW)
Turbine Discharge (m3/s)
Effective Head (m)
Intake Facilities
Height of Dam (m)
Length of Dam (m)
Headrace
Length of Headrace (m)
Penstock
Diameter of Penstock (m)
Distribution
Number of Households (kk)
Distance to the furthest house from P.S
In addition, since indirect costs, such as tax, contractor fee, design cost, and supervisor
fee, are contained in the cost of construction calculated by Fig 8.1.2, when a part of
these indirect costs can be omitted, examination is required separately.
- 8-1 -


Chapter 8
Table8.1.2 Method to make a trial calculation of construction cost in Rough Planning Stage
(Rp)
No.
Description
(1) PREPARATORY WORKS
Formulation
{(2)+(3)+(4)+(5)}0.1
(2) CIVIL WORKS

Intake Facilities
Gabion Dam
210,000(HL)
Stone Masonry Dam
785,000(HL)+850,000
Concrete Dam
1,650,000(HL)
Long or Mid-Penstock type
0.504
60,300,000Q
Settling Basin
Remarks
Transportation, Clearing,
Temporally Works
H : Height of Dam(m)
L : Length of Dam(m)
3
Q : Turbine Discharge(m /s)

(Back to System Layout : Page42)
Short Penstock type

0.794
54,200,000Q
Q : Turbine Discharge(m3/s)
(Back to System Layout : Page41)
Headrace
435,000Q0.18L
Q : Turbine Discharge(m3/s)
L : Length of Headrace(m)
Head Tank
Penstock
47,600,000Q
Civil Works
0.571
L
775,000
Pestock
15,000(Unit waight)L
0.456
4,890,000P
Power House Base
0.5
Power House Building

(3) ELECTROMECHANICAL
WORKS
2,460,000P+20,350,000
(4) DISTRIBUTION WORKS
14,300X0.5541
(5) CONSUMER CONNECTION
428,000X+31,900,000
(6) OTHERS
{(2)+(3)+(4)+(5)}0.05
TOTAL
0.56
75,710,000(P/He)
(1)+(2)+(3)+(4)+(5)+(6)
- 8-2 -
Q : Turbine Discharge(m /s)

: Daiameter of Penstock (m)
L : Length of Penstock (m)
L : Length of Penstock (m)
P : Maximum Output(kW)
(Include Tail race)
Closs flow Turbine T-13
He : Effective Head(m)
X : Number of Household
2
Distance
X : Number of Household


Chapter 8
100,000,000
90,000,000
Concrete Dam
(H
L
)
80,000,000
85
)+
(H
st(R
Stone Masonry
t(R
p)
=
78
5,
00
50,000,000
Co
os
40,000,000
Cost (Rp)
p)
60,000,000
0,
=1
00
,65
0
, 00
70,000,000
30,000,000
20,000,000
y=
10,000,000
(H
00
0
,
0
1
2
L)
Gabion Dam
0
0
10
20
30
40
50
60
70
HL
Fig8.1.1 Cost of Intake facilities

Notes: For a trial calculation of construction cost in Rough Planning Stage
- 8-3 -
80


Chapter 8
80,000,000
70,000,000
60,000,000
Long or Mid-length Penstock type

0.504
Cost(Rp) =60,300,000Q
Cost (Rp)
50,000,000
40,000,000
30,000,000
Short Penstock type

0.794
Cost(Rp) = 54,200,000Q
20,000,000
10,000,000
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Q (m /s)
Fig8.1.2 Cost of Settling Basin

- 8-4 -


Chapter 8
500,000
Unit Cost(Rp/m) = 435,000Q
0.18
450,000
Unit Cost (Rp/m)
400,000
350,000
300,000
250,000
200,000
0
0.2
0.4
0.6
0.8
Q (m /s)
Fig8.1.3 Unit Cost of Headrace

- 8-5 -
1.2


Chapter 8
70,000,000
0.5
Cost(Rp) = 47,600,000Q
60,000,000
50,000,000
Cost (Rp)
40,000,000
30,000,000
20,000,000
10,000,000
0
0
0.2
0.4
0.6
0.8
Q (m /s)
Fig8.1.4 Cost of Head tank

- 8-6 -
1.2


Chapter 8
1,200,000
Cost(Rp) = 775,000
0.571
1,000,000
Cost (Rp)
800,000
600,000
400,000
200,000
0
0.2
0.4
0.6
0.8
1.2
Daiameter of Penstock (m)
Fig8.1.5 Cost of Penstock (Civil Works)

- 8-7 -
1.4


Chapter 8
100
90
t=3mm
y = 0.07417 + 0.00133
t=4mm
y = 0.0989 - 0.0021
80
t=5mm
y = 0.1236 + 0.0012
t=5mm
Unit vilume waigth (kg/m)
70
60
t=4mm
50
t=3mm
40
30
20
10
0
100
200
300
400
500
600
700
Daiameter of Penstock (mm)
Fig8.1.6 Unit volume waight of Penstock

- 8-8 -
800


Chapter 8
40,000,000
0.456
Cost(Rp) = 4,890,000P
35,000,000
30,000,000
Cost (Rp)
25,000,000
20,000,000
15,000,000
10,000,000
5,000,000
0
0
10
20
30
40
50
60
70
80
P (kW)
Fig8.1.7 Cost of Power house Base

(Inc. Tail race)
- 8-9 -


Chapter 8
250,000,000
Cost(Rp) = 2,460,000P + 20,350,000
200,000,000
Cost (Rp)
150,000,000
100,000,000
50,000,000
0
0
10
20
30
40
50
60
P (kW)
Fig8.1.8 Cost of Power house builiding

- 8-10 -
70


Chapter 8
400,000,000
Cost(Rp) = 75,710,000 (P/He)
0.56
350,000,000
300,000,000
Cost (Rp)
250,000,000
200,000,000
150,000,000
100,000,000
50,000,000
0
0
10
12
P/He
Fig8.1.9 Cost of Electromechanical Works

- 8-11 -
14


Chapter 8
800,000,000
Cost(Rp) = 14300x
0.5541
700,000,000
600,000,000
Cost (Rp)
500,000,000
400,000,000
300,000,000
200,000,000
100,000,000
0
0
50,000,000
100,000,000
150,000,000
200,000,000
250,000,000
x = (Number of Household) * (Distance) ^ 2
Fig8.1.10 Cost of Distribution Works

- 8-12 -


Chapter 8
350,000,000
Cost (Rp) = 428000 x + 31900000

300,000,000
250,000,000
Cost (Rp)
200,000,000
150,000,000
100,000,000
50,000,000
0
0
100
200
300
400
500
600
700
Number of Household
Fig8.1.11 Cost of Consumer Connection

- 8-13 -


Chapter 8
8.2 Cost Estimation for Detail Design Stage

Construction cost consists of items as shown in Table8.2.1.
Table8.2.1 Construction Cost
No.
Item
Direct cost of construction
1
PREPARATORY WORKS
2 CIVIL WORKS
3
ELECTRO-MECHANICAL WORKS
4 DISTRIBUTION WORKS
5 CONSUMER CONNECTION
SUB TOTAL(A)
Indirect cost
1 DESIGN FEE
2 SUPERVISOR FEE
3 MANAGEMENT FEE
4 TAX
SUB TOTAL(B)
Cost
Addition item
Addition item
Addition item
Addition item
Addition item
510% of SUB TOTAL(A)

12.5% of SUB TOTAL(A)
TOTAL
8.2.1 Items
Typical items of a direct cost are shown below.
(1) Preparatory works
Preparatory works consist of item as follows.
- Location setting out
- Felling and measurement
- Equipment & materials mobilization
(2) Civil works
Civil works consist of item as follows.
- Intake facilities
- Settling basin
- Headrace
- Head tank
- 8-14 -


Chapter 8
Spillway
Penstock and foundation
Powerhouse base
Tailrace
Power house building
Finishing
(3) Electro-mechanical works

Electro-mechanical works consist of item as follows.
-
Turbine
Controller
Dummy load
Generator
Accessories, spare parts and tools
Set up and installation
Transportation and packing
Testing
Pre commissioning trial run
(4) Distribution works

Distribution works consist of item as follows.
- Transmission pole
- Cable
- Transformer
- Accessories
(5) Consumer connection
- Cable
- Switch
- Accessories
- 8-15 -


Chapter 8
8.2.2 Quantity
In order to calculate direct cost of construction, it is necessary to calculate the quantity
for every work or material based on design. For example, in case of headrace of
masonry, quantity will be calculated for excavation, foundation rubble stone, stone
masonry, backfill, and plaster like Fig 8.2.1.
Foundation rubble stone

Excavation
Plaster
Fig 8.2.1
Stone masonry
Backfill
The example of works which should be calculatedHeadrace
With a natural thing, these items change according to a kind and the quality of structure.
For example, in Intake, the item that should calculate will be changed according to type
of dam like Table 8.2.2. And in Headrace, the item which should calculate will be
changed according to the quality of the material of Headrace like Table 8.2.3.
Gabion dam
Excavation (m3)
Backfill (m3)
Gabion (m3)
Table 8.2.2 Quantity of dam

Masonry dam
- Excavation (m3)
- Backfill (m3)
- Foundation
Rubble
Stone (m3)
- Stone masonry (m3)
- Plaster (m2)
- Stoplog (m2)
- Gabion (m3)
- 8-16 -
Concrete dam
Excavation (m3)
Backfill (m3)
Sand filling (m3)
Concrete (m3)
Plaster (m2)
Stoplog (m2)
Gabion (m3)

Simple earth channel

Excavation (m3)

Chapter 8
Table8.2.3 Quantity of headrace

Masonry channel
- Excavation (m3)
- Backfill (m3)
- Foundation
Rubble
Stone (m3)
- Stone masonry (m3)
- Plaster (m2)
Concrete channel
Excavation (m3)
Backfill (m3)
Sand filling (m3)
Concrete (m3)
Plaster (m2)
This is the same for other structures too, and care is taken not to omit ay items that
should be added up based on drawings.Ref 8.1 Breakdown of Construction Cost of
Pilot Project
8.2.3 Unit Cost

Table 8.2.4 shows standard unit cost of civil work of PU. Unit Price of Table 8.2.4 is
price of Tana-Toraja. Since unit cost changes according to various situations of each
area, it is desirable to perform unit cost setup enough in consideration of the local
characteristics.
- 8-17 -


Chapter 8
Table8.2.4 Unit cost of PU (Toraja)

Koef.
Unit
Unit Price
(Rp)
Unit Cost
(Rp)
Excavation(m3)
unskill labour
foreman
tools
Total
0.625
0.062
1.000
man
man
ls
15,000
17,500
12,000
22,500
9,375
1,085
12,000
22,460
Backfill (m 3)
unskill labour
foreman
tools
Total
0.192
0.019
1.000
man
man
ls
15,000
17,500
12,000
15,200
2,880
333
12,000
15,213
Sand Filling (m 3)
sand
unskill labour
foreman
Total
1.200
0.150
0.010
m
man
man
40,000
15,000
17,500
50,400
48,000
2,250
175
50,425
Fondation Rubble Stone (m3)

stone
sand
unskill labour
skill labour
foreman
Total
1.200
0.400
1.125
0.563
0.056
m3
m3
man
man
man
50,000
40,000
15,000
25,000
17,500
108,000
60,000
16,000
16,875
14,075
980
107,930
1.200
3.520
0.380
2.250
1.125
0.113
0.017
m3
zak
m3
man
man
man
man
50,000
26,500
40,000
15,000
25,000
30,000
17,500
234,000
60,000
93,280
15,200
33,750
28,125
3,390
298
234,043
Stone Masonry 1:2 (m3)

stone
PC
sand
unskill labour
skill labour
chief labor
foreman
Total

stone
PC
sand
unskill labour
skill labour
chief labor
foreman
Total
1.200
2.840
0.400
2.250
1.125
0.113
0.017
m
zak
m3
man
man
man
man
50,000
26,500
40,000
15,000
25,000
30,000
17,500
217,000
60,000
75,260
16,000
33,750
28,125
3,390
298
216,823

stone
PC
sand
unskill labour
skill labour
chief labor
foreman
Total
1.200
2.500
0.420
2.250
1.125
0.113
0.017
m3
zak
m3
man
man
man
man
50,000
26,500
40,000
15,000
25,000
30,000
17,500
209,000
60,000
66,250
16,800
33,750
28,125
3,390
298
208,613
- 8-18 -
Remark

Surface Finish (m2)

PC
sand
meduam skill labour
skill labour
chief labor
foreman
Total
Gabion (m 3)
stone
wire cage
unskill labour
skill labour
foreman
Total
Stoplogs (unit)
wood
carpenter
labour
foreman
tools
Total

Chapter 8
Koef.
Unit
Unit Price
(Rp)
0.237
0.019
0.286
0.214
0.021
0.020
zak
m3
man
man
man
man
26,500
40,000
20,000
25,000
30,000
17,500
1.200
3.500
0.450
0.200
0.020
m
kg
man
man
man
50,000
7,000
15,000
25,000
17,500
0.048
1.000
2.000
0.100
1.000
m3
man
man
man
ls
4,150,000
25,000
15,000
17,500
25,000
Working floor (m 2)
PC
sand for concrete
split/gravel
tools
labour
skill labour
chief labor
foreman
Total
3.956
0.550
0.930
1.000
2.000
0.500
0.050
0.010
zak
m3
m3
ls
man
man
man
man
26,500
50,000
75,000
15,000
15,000
25,000
30,000
17,500
Rainforce Concrete K225(m3)

PC
split/gravel
sand for concrete
labour
skill labour
chief labor
foreman
tools
steel bar concrete
wire
labour for steel concrete
chief for steel concrete
unskill labour
nail
carpenter
chief of carpenter
Total
7.896
0.810
0.490
3.000
0.500
0.050
0.110
1.000
175.0
2.000
6.750
2.250
8.750
4.000
5.000
0.500
zak
m3
m3
man
man
man
man
ls
kg
kg
man
man
man
kg
man
man
26,500
75,000
50,000
15,000
25,000
30,000
17,500
75,000
7,000
9,000
25,000
30,000
15,000
7,500
25,000
30,000
- 8-19 -
Unit Cost
(Rp)
Remark
19,100
6,281
760
5,720
5,350
630
350
19,091
96,600
60,000
24,500
6,750
5,000
350
96,600
281,000
199,200
25,000
30,000
1,750
25,000
280,950
261,000
104,834
27,500
69,750
15,000
30,000
12,500
1,500
175
261,259
2,211,000
209,244
60,750
24,500
45,000
12,500
1,500
1,925 con.+form
75,000
1,225,000
18,000
168,750
67,500
131,250 con.+form
30,000
125,000
15,000
2,210,919


Chapter 8
[Ref. 8-1 Cross-sectional method to calculate quantity]

It is convenient to use the cross-sectional method when calculating complicated quantities such a
headrace. When you want to calculate the quantity of excavation of headrace as shown in the
following figure, first, you draw a sectional view for every changing point of cross-sectional
form, and the excavation area for every section is calculated using planimeter, etc.
- 8-20 -


Chapter 8
Next, you can make the next table from the relation between the area of each section, and
distance.
Section name Excavation Area Average Area
Distance
Volume
2.00m
2.690m
3.00m
4.125m
3.00m
3.735m
2.00m
2.180m
A-A
B-B
C-C
D-D
E-E
1.31 m
1.345m
1.38m
1.375m
1.37m
1.245m
1.12m
1.090m
3
3
3
3
1.06m
Total
12.73m
This cross-sectional method is applicable not only to excavation area but also to calculation
quantities of backfill or masonry.
- 8-21 -


Chapter 8
[Ref. 8-2 The example of bill of quantity]

No
Description
PREPARATORY WORKS
II
CIVIL WORKS
1 Intake Facilities include setling basin
a. Excavation
b. Backfill
c. Foundation rubble stone
d. Stone Masonry 1 : 2
e. Plaster
f. Gabions
w
h
2
g. Stoplogs (80 x 100 ) cm
w
h
2
h. Flushing Gate (60 x 210 ) cm
i. Screen
Unit
Quantity
Unit Price
Rp
m
3
m
3
m
3
m
2
m
3
m
unit
unit
2
m
sub total
2
a.
b.
c.
d.
e.
f.
Headrace
Excavation
Backfill
Stone Masonry 1 : 4
Plaster
Stoplogs (80w x 100h) cm2
m
3
m
3
m
3
m
2
m
unit
sub total
3
a.
b.
c.
d.
e.
f.
g.
Head Tank
Excavation
Backfill
Stone Masonry 1 : 3
Plaster
w
h
2
Gate (60 x 200 ) cm
Screen
4
a.
b.
c.
d.
e.
Spillway Channel
Excavation
Backfill
Stone Masonry 1 : 4
Plaster
5
a.
b.
c.
d.
e.
f.
g.
h.
I.
j.
k.
l.
Penstock and Foundation

Excavation
Reinforced Concrete
Working floor
Sand filling
Plaster
Penstock set work
Welded steel
Butterfly valve
Reducer pipe
Clamp penstock
Bend degree angle
Anchor bolt
m
3
m
3
m
3
m
2
m
unit
2
m
sub total
3
m
3
m
3
m
3
m
2
m
sub total
3
m
3
m
3
m
3
m
2
m
1
m
1
m
unit
unit
pcs
pcs
pcs
sub total
- 8-22 -
Amount
Rp
Total Price
Rp

No
Description
6
a.
b.
c.
d.
e.
f.
g.
h.
Power House Base + Tail Race

Excavation
Backfill
Sand filling
Working floor
Reinforce Concrete
Stone Masonry 1 : 4
Surface finish
Unit
Quantity

Chapter 8
Unit Price
Rp
m
3
m
3
m
3
m
3
m
3
m
3
m
2
m
sub total
7 Power House
a. Building
sub total
8
a.
b.
c.
Finishing
Penstock painting
Building Painting
Service Walkway
m
ls
1
m
sub total
III
MECHANICAL & ELECTRICAL

1 Crossflow Turbine
a. Turbine T13 bo. 600 mm
b. Turbine base frame
c. Pulley of turbine
e. Flexible Coupling
unit
unit
unit
unit
f.
g.
h.
I.
j.
k.
l.
unit
unit
unit
unit
ls
ls
unit
Plummer Block Bearing Set

Flat belt
Fence Guard
adapter pipe
Dynamic Balancing
Heat treatment
Pressure gauge
sub total
2 Electronic Load Controller
unit
sub total
3 Ballast Load
a. Air Heater (54 kVA)
b. Housing Ballast
unit
unit
sub total
4
a.
b.
c.
Generator
Syncronous Generator Stamford
Generator base frame
Pulley of generator
unit
unit
unit
sub total
5 Accessories, Spare parts & Tools
unit
sub total
6 Set up & Installation
ls
sub total
7 Transportation & Packaging
ls
sub total
8 Testing (welding)
ls
sub total
9 Pre commissioning Trial Run
ls
sub total
- 8-23 -
Amount
Rp
Total Price
Rp

No
IV
Description
Unit
DISTRIBUTION WORKS
a. Transmission pole
2
b. Twisted Cable 4 * 70 mm
2
c. Twisted Cable 4 * 35 mm
2
d. Twisted Cable 2 * 16 mm
e. Accessories
f. Installation expense
pcs
1
m
1
m
1
m
ls
ls
CONSUMER CONNECTION
2
a. NYM Cable 2 * 1.5 mm
2
b. NYM Cable 3 * 1.5 mm
c. Electric Socket
d. Series Switch
e. Single Switch
f. Connector
g. Service Wedge Clamp
h. Cable Clam
i. Plafond Fitting
j. Hanger Fitting
k. Rosset Wood
l. Cellophane Tape
m. Screw
n. T - dus
o. MCB and housing
2
p. Twisted Cable 2 * 10 mm
q. Grounding
r. Installation Expense
s MCCB Group
m
1
m
pcs
pcs
pcs
pcs
pcs
pack
pcs
pcs
pcs
pcs
pack
pcs
unit
1
m
unit
unit
unit
Quantity

Chapter 8
Unit Price
Rp
Amount
Rp
TOTAL Rp
- 8-24 -
Total Price
Rp

15.Cpt 8 Cost Estimation

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15.Cpt 8 Cost Estimation

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Study on Rural Energy Supply with Utilization of Renewable Energy

in Rural Areas in the Republic of Indonesia

Manual for Micro-hydro power Development

8.1 Cost Estimation for Rough Planning Stage

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

(2) CIVIL WORKS

Q : Turbine Discharge(m /s)

Short Penstock type

Power House Base

Power House Building

(4) DISTRIBUTION WORKS

(5) CONSUMER CONNECTION

Q : Turbine Discharge(m /s)

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Fig8.1.1 Cost of Intake facilities

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Long or Mid-length Penstock type

Short Penstock type

Fig8.1.2 Cost of Settling Basin

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Unit Cost(Rp/m) = 435,000Q

Unit Cost (Rp/m)

Fig8.1.3 Unit Cost of Headrace

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Fig8.1.4 Cost of Head tank

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Daiameter of Penstock (m)

Fig8.1.5 Cost of Penstock (Civil Works)

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Unit vilume waigth (kg/m)

Daiameter of Penstock (mm)

Fig8.1.6 Unit volume waight of Penstock

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Fig8.1.7 Cost of Power house Base

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Cost(Rp) = 2,460,000P + 20,350,000

Fig8.1.8 Cost of Power house builiding

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Cost(Rp) = 75,710,000 (P/He)

Fig8.1.9 Cost of Electromechanical Works

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

x = (Number of Household) * (Distance) ^ 2

Fig8.1.10 Cost of Distribution Works

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

Cost (Rp) = 428000 x + 31900000

Fig8.1.11 Cost of Consumer Connection

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development

8.2 Cost Estimation for Detail Design Stage

510% of SUB TOTAL(A)

Study on Rural Energy Supply with Utilization of Renewable Energy

Manual for Micro-hydro power Development