Study on Rural Energy Supply with Utilization of Renewable Energy Manual for Micro-hydro power Development

in Rural Areas in the Republic of Indonesia Chapter 8

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.

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Table8.1.2 Method to make a trial calculation of construction cost in Rough Planning Stage

(Rp)
No. Description Formulation Remarks
(1) PREPARATORY WORKS {(2)+(3)+(4)+(5)}×0.1 Transportation, Clearing,
Temporally Works
(2) CIVIL WORKS ①～⑦
① Intake Facilities Gabion Dam H : Height of Dam(m)
210,000×(H×L) L : Length of Dam(m)
Stone Masonry Dam H : Height of Dam(m)
785,000×(H×L)+850,000 L : Length of Dam(m)
Concrete Dam H : Height of Dam(m)
1,650,000×(H×L) L : Length of Dam(m)
② Settling Basin Long or Mid-Penstock type Q : Turbine Discharge(m /s)
3
0.504
60,300,000×Q (Back to System Layout : Page4-
2)
Short Penstock type Q : Turbine Discharge(m3/s)
0.794
54,200,000×Q (Back to System Layout : Page4-
1)
③ Headrace 435,000×Q0.18×L Q : Turbine Discharge(m3/s)
L : Length of Headrace(m)
④ Head Tank 47,600,000×Q
0.5
Q : Turbine Discharge(m /s)
3

⑤ Penstock Civil Works φ : Daiameter of Penstock (m)

0.571 L : Length of Penstock (m)
775,000×φ ×L
Pestock L : Length of Penstock (m)
15,000×(Unit waight)×L
⑥ Power House Base 4,890,000×P
0.456 P : Maximum Output(kW)
(Include Tail race)
⑦ Power House Building 2,460,000×P+20,350,000 P : Maximum Output(kW)
(3) ELECTROMECHANICAL 0.56 Closs flow Turbine T-13
75,710,000×(P/√He)
WORKS P : Maximum Output(kW)
He : Effective Head(m)
(4) DISTRIBUTION WORKS 14,300×X0.5541 X : Number of Household×
2
Distance
(5) CONSUMER CONNECTION 428,000X+31,900,000 X : Number of Household
(6) OTHERS {(2)+(3)+(4)+(5)}×0.05

TOTAL (1)+(2)+(3)+(4)+(5)+(6)

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100,000,000

90,000,000

Concrete Dam

80,000,000

)
×L
(H
0＊
70,000,000

, 00
0
,65

0
00
=1

60,000,000

0,
85
p)

)+
st(R

×L
(H
Cost (Rp)

Co

0＊
50,000,000

00
5,
78

Stone Masonry
=
p)
t(R

40,000,000
os
C

30,000,000

20,000,000

(H ×L)
1 0 ,0 00 ＊
y= 2
10,000,000 Gabion Dam

0
0 10 20 30 40 50 60 70 80
H×L

Fig8.1.1 Cost of Intake facilities

Notes: For a trial calculation of construction cost in Rough Planning Stage

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80,000,000

70,000,000

60,000,000

Long or Mid-length Penstock type

0.504
50,000,000 Cost(Rp) =60,300,000＊Q
Cost (Rp)

40,000,000

30,000,000

Short Penstock type

0.794
20,000,000 Cost(Rp) = 54,200,000＊Q

10,000,000

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
3
Q (m /s)

Fig8.1.2 Cost of Settling Basin

Notes: For a trial calculation of construction cost in Rough Planning Stage

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500,000

0.18
Unit Cost(Rp/m) = 435,000＊Q

450,000

400,000
Unit Cost (Rp/m)

350,000

300,000

250,000

200,000
0 0.2 0.4 0.6 0.8 1 1.2
3
Q (m /s)

Fig8.1.3 Unit Cost of Headrace

Notes: For a trial calculation of construction cost in Rough Planning Stage

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70,000,000

0.5
Cost(Rp) = 47,600,000＊Q

60,000,000

50,000,000

40,000,000
Cost (Rp)

30,000,000

20,000,000

10,000,000

0
0 0.2 0.4 0.6 0.8 1 1.2
3
Q (m /s)

Fig8.1.4 Cost of Head tank

Notes: For a trial calculation of construction cost in Rough Planning Stage

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1,200,000

0.571
Cost(Rp) = 775,000φ

1,000,000

800,000
Cost (Rp)

600,000

400,000

200,000

0
0.2 0.4 0.6 0.8 1 1.2 1.4
Daiameter of Penstock φ(m)

Fig8.1.5 Cost of Penstock (Civil Works)

Notes: For a trial calculation of construction cost in Rough Planning Stage

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100

t=3mm
90
y = 0.07417 φ + 0.00133

t=4mm
y = 0.0989φ - 0.0021
80
t=5mm t=5mm
y = 0.1236φ + 0.0012

70

60
Unit vilume waigth (kg/m)

t=4mm

50

t=3mm
40

30

20

10

0
100 200 300 400 500 600 700 800
Daiameter of Penstock φ(mm)

Fig8.1.6 Unit volume waight of Penstock

Notes: For a trial calculation of construction cost in Rough Planning Stage

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40,000,000

0.456
Cost(Rp) = 4,890,000＊P

35,000,000

30,000,000

25,000,000
Cost (Rp)

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)
Notes: For a trial calculation of construction cost in Rough Planning Stage

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250,000,000

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

200,000,000

150,000,000
Cost (Rp)

100,000,000

50,000,000

0
0 10 20 30 40 50 60 70
P (kW)

Fig8.1.8 Cost of Power house builiding

Notes: For a trial calculation of construction cost in Rough Planning Stage

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400,000,000

0.56
Cost(Rp) = 75,710,000 (P/√He)

350,000,000

300,000,000

250,000,000
Cost (Rp)

200,000,000

150,000,000

100,000,000

50,000,000

0
0 2 4 6 8 10 12 14
P/√He

Fig8.1.9 Cost of Electromechanical Works

Notes: For a trial calculation of construction cost in Rough Planning Stage

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800,000,000

0.5541
Cost(Rp) = 14300x

700,000,000

600,000,000

500,000,000
Cost (Rp)

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

Notes: For a trial calculation of construction cost in Rough Planning Stage

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350,000,000

Cost (Rp) = 428000 x + 31900000

300,000,000

250,000,000

200,000,000
Cost (Rp)

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

Notes: For a trial calculation of construction cost in Rough Planning Stage

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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 Cost
Direct cost of construction
1 PREPARATORY WORKS Addition item
2 CIVIL WORKS Addition item
3 ELECTRO-MECHANICAL WORKS Addition item
4 DISTRIBUTION WORKS Addition item
5 CONSUMER CONNECTION Addition item
SUB TOTAL(A)
Indirect cost
1 DESIGN FEE 5～10% of SUB TOTAL(A)
2 SUPERVISOR FEE 5～10% of SUB TOTAL(A)
3 MANAGEMENT FEE 5～10% of SUB TOTAL(A)
4 TAX 12.5% of SUB TOTAL(A)
SUB TOTAL(B)
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

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- 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

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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 Backfill Stone masonry

Fig 8.2.1 The example of works which should be calculated（Headrace）

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.

Table 8.2.2 Quantity of dam

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

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Table8.2.3 Quantity of headrace

Simple earth channel Masonry channel Concrete channel
- Excavation (m3) - Excavation (m3) - Excavation (m3)
- Backfill (m3) - Backfill (m3)
- Foundation Rubble - Sand filling (m3)
Stone (m3) - Concrete (m3)
- Stone masonry (m3) - Plaster (m2)
- 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.

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Table8.2.4 Unit cost of PU (Toraja)

Koef. Unit Unit Price Unit Cost Remark
(Rp) (Rp)
Excavation(m3) 22,500
unskill labour 0.625 man 15,000 9,375
foreman 0.062 man 17,500 1,085
tools 1.000 ls 12,000 12,000
Total 22,460
Backfill (m 3) 15,200
unskill labour 0.192 man 15,000 2,880
foreman 0.019 man 17,500 333
tools 1.000 ls 12,000 12,000
Total 15,213
Sand Filling (m 3) 50,400
3
sand 1.200 m 40,000 48,000
unskill labour 0.150 man 15,000 2,250
foreman 0.010 man 17,500 175
Total 50,425
Fondation Rubble Stone (m3) 108,000
stone 1.200 m3 50,000 60,000
sand 0.400 m3 40,000 16,000
unskill labour 1.125 man 15,000 16,875
skill labour 0.563 man 25,000 14,075
foreman 0.056 man 17,500 980
Total 107,930
Stone Masonry 1:2 (m3) 234,000
stone 1.200 m3 50,000 60,000
PC 3.520 zak 26,500 93,280
sand 0.380 m3 40,000 15,200
unskill labour 2.250 man 15,000 33,750
skill labour 1.125 man 25,000 28,125
chief labor 0.113 man 30,000 3,390
foreman 0.017 man 17,500 298
Total 234,043
Stone Masonry 1:3 (m3) 217,000
3
stone 1.200 m 50,000 60,000
PC 2.840 zak 26,500 75,260
sand 0.400 m3 40,000 16,000
unskill labour 2.250 man 15,000 33,750
skill labour 1.125 man 25,000 28,125
chief labor 0.113 man 30,000 3,390
foreman 0.017 man 17,500 298
Total 216,823
Stone Masonry 1:4 (m3) 209,000
stone 1.200 m3 50,000 60,000
PC 2.500 zak 26,500 66,250
sand 0.420 m3 40,000 16,800
unskill labour 2.250 man 15,000 33,750
skill labour 1.125 man 25,000 28,125
chief labor 0.113 man 30,000 3,390
foreman 0.017 man 17,500 298
Total 208,613

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Koef. Unit Unit Price Unit Cost Remark

(Rp) (Rp)
Surface Finish (m2) 19,100
PC 0.237 zak 26,500 6,281
sand 0.019 m3 40,000 760
meduam skill labour 0.286 man 20,000 5,720
skill labour 0.214 man 25,000 5,350
chief labor 0.021 man 30,000 630
foreman 0.020 man 17,500 350
Total 19,091
Gabion (m 3) 96,600
3
stone 1.200 m 50,000 60,000
wire cage 3.500 kg 7,000 24,500
unskill labour 0.450 man 15,000 6,750
skill labour 0.200 man 25,000 5,000
foreman 0.020 man 17,500 350
Total 96,600
Stoplogs (unit) 281,000
wood 0.048 m3 4,150,000 199,200
carpenter 1.000 man 25,000 25,000
labour 2.000 man 15,000 30,000
foreman 0.100 man 17,500 1,750
tools 1.000 ls 25,000 25,000
Total 280,950
Working floor (m 2) 261,000
PC 3.956 zak 26,500 104,834
sand for concrete 0.550 m3 50,000 27,500
split/gravel 0.930 m3 75,000 69,750
tools 1.000 ls 15,000 15,000
labour 2.000 man 15,000 30,000
skill labour 0.500 man 25,000 12,500
chief labor 0.050 man 30,000 1,500
foreman 0.010 man 17,500 175
Total 261,259
Rainforce Concrete K225(m3) 2,211,000
PC 7.896 zak 26,500 209,244
split/gravel 0.810 m3 75,000 60,750
sand for concrete 0.490 m3 50,000 24,500
labour 3.000 man 15,000 45,000
skill labour 0.500 man 25,000 12,500
chief labor 0.050 man 30,000 1,500
foreman 0.110 man 17,500 1,925 con.+form
tools 1.000 ls 75,000 75,000
steel bar concrete 175.0 kg 7,000 1,225,000
wire 2.000 kg 9,000 18,000
labour for steel concrete 6.750 man 25,000 168,750
chief for steel concrete 2.250 man 30,000 67,500
unskill labour 8.750 man 15,000 131,250 con.+form
nail 4.000 kg 7,500 30,000
carpenter 5.000 man 25,000 125,000
chief of carpenter 0.500 man 30,000 15,000
Total 2,210,919

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[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.

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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

① ② ③ ②×③
2
A-A 1.31 m
2 3
1.345m 2.00m 2.690m
2
B-B 1.38m
2 3
1.375m 3.00m 4.125m
2
C-C 1.37m
2 3
1.245m 3.00m 3.735m
2
D-D 1.12m
2 3
1.090m 2.00m 2.180m
2
E-E 1.06m
3
Total 12.73m

This cross-sectional method is applicable not only to excavation area but also to calculation
quantities of backfill or masonry.

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

No Description Unit Quantity Unit Price Amount Total Price

Rp Rp Rp
I PREPARATORY WORKS

II CIVIL WORKS
1 Intake Facilities include setling basin
3
a. Excavation m
3
b. Backfill m
3
c. Foundation rubble stone m
3
d. Stone Masonry 1 : 2 m
2
e. Plaster m
3
f. Gabions m
w h 2
g. Stoplogs (80 x 100 ) cm unit
w h 2
h. Flushing Gate (60 x 210 ) cm unit
2
i. Screen m
sub total
2 Headrace
3
a. Excavation m
3
b. Backfill m
3
c. Foundation rubble stone m
3
d. Stone Masonry 1 : 4 m
2
e. Plaster m
f. Stoplogs (80w x 100h) cm2 unit
sub total

3 Head Tank
3
a. Excavation m
3
b. Backfill m
3
c. Foundation rubble stone m
3
d. Stone Masonry 1 : 3 m
2
e. Plaster m
w h 2
f. Gate (60 x 200 ) cm unit
2
g. Screen m
sub total
4 Spillway Channel
3
a. Excavation m
3
b. Backfill m
3
c. Foundation rubble stone m
3
d. Stone Masonry 1 : 4 m
2
e. Plaster m
sub total
5 Penstock and Foundation
3
a. Excavation m
3
b. Reinforced Concrete m
3
c. Working floor m
3
d. Sand filling m
2
e. Plaster m
1
f. Penstock set work m
1
g. Welded steel m
h. Butterfly valve unit
I. Reducer pipe unit
j. Clamp penstock pcs
k. Bend degree angle pcs
l. Anchor bolt pcs
sub total

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No Description Unit Quantity Unit Price Amount Total Price

Rp Rp Rp
6 Power House Base + Tail Race
3
a. Excavation m
3
b. Backfill m
3
c. Sand filling m
3
d. Working floor m
3
e. Reinforce Concrete m
3
f. Foundation rubble stone m
3
g. Stone Masonry 1 : 4 m
2
h. Surface finish m
sub total
7 Power House
2
a. Building m
sub total
8 Finishing
1
a. Penstock painting m
b. Building Painting ls
1
c. Service Walkway m
sub total

III MECHANICAL & ELECTRICAL

1 Crossflow Turbine
a. Turbine T13 bo. 600 mm unit
b. Turbine base frame unit
c. Pulley of turbine unit
e. Flexible Coupling unit

f. Plummer Block Bearing Set unit

g. Flat belt unit
h. Fence Guard unit
I. adapter pipe unit
j. Dynamic Balancing ls
k. Heat treatment ls
l. Pressure gauge unit
sub total

2 Electronic Load Controller unit

sub total
3 Ballast Load
a. Air Heater (54 kVA) unit
b. Housing Ballast unit
sub total
4 Generator
a. Syncronous Generator Stamford unit
b. Generator base frame unit
c. Pulley of generator 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

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No Description Unit Quantity Unit Price Amount Total Price

Rp Rp Rp
IV DISTRIBUTION WORKS
a. Transmission pole pcs
2 1
b. Twisted Cable 4 * 70 mm m
2 1
c. Twisted Cable 4 * 35 mm m
2 1
d. Twisted Cable 2 * 16 mm m
e. Accessories ls
f. Installation expense ls

V CONSUMER CONNECTION
2 1
a. NYM Cable 2 * 1.5 mm m
2 1
b. NYM Cable 3 * 1.5 mm m
c. Electric Socket pcs
d. Series Switch pcs
e. Single Switch pcs
f. Connector pcs
g. Service Wedge Clamp pcs
h. Cable Clam pack
i. Plafond Fitting pcs
j. Hanger Fitting pcs
k. Rosset Wood pcs
l. Cellophane Tape pcs
m. Screw pack
n. T - dus pcs
o. MCB and housing unit
2 1
p. Twisted Cable 2 * 10 mm m
q. Grounding unit
r. Installation Expense unit
s MCCB Group unit

TOTAL Rp

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