Detailed Cost Estimation for 6.
6kV Incomer Panel+ Trafo Feeder
Specifications:
Type: 8BK80+3AH3 Design
Dimensions: 800mm (Width) x 2300mm (Height) x 2220mm (Depth)
CT Fault: 40kA for 3 Sec
Busbar: MBB-1x100x10 Copper, 1250A
Ambient Temperature: 50°C
Accessories: Heat shrinkable sleeves, Feeder connections as per CT rating
1. Material Cost
a. Panel Structure
Material: CRCA sheet steel, powder-coated.
Size: (800 × 2300 × 2220) mm. Approx. sheet area = 20 m².
Sheet Thickness: 2 mm.
Weight Calculation:
• Weight = Sheet area × Thickness × Density of steel (7.85 kg/m³)
• Weight = 20 × 0.002 × 7.85 = 314 kg.
Cost of Steel: Approx. rate: ₹80/kg (inclusive of cutting, bending, and powder
coating).
Cost = 314 kg × ₹80 = ₹25,120
b. Copper Busbar
Specification: 1x100x10 mm, MBB, 1250A.
Weight Calculation:
• Length = Approx. 15 m (as per design allowances).
• Weight per meter = Width × Thickness × Density (8.9 kg/m³).
• Weight/m = 0.1 m × 0.01 m × 8.9 = 8.9 kg/m.
• Total Weight = 8.9 kg/m × 15 m = 133.5 kg.
Copper Rate: ₹870/kg.
Cost = 133.5 × ₹870 = ₹1,16,145
Heat Shrinkable Sleeves: Approx. ₹200/m for 15 m = ₹3,000
c. Current Transformers (CTs)
Specification: Fault current = 40 kA for 3 seconds.
Quantity: 3 CTs (one for each phase).
Approx. Cost: ₹110,000/CT.
Total Cost = 3 × ₹110,000 = ₹330,000
Protection Relay
Specification: Numerial, Earth, overcurrent
Quantity: Mandatory Relays: 5 (Overcurrent, Earth Fault, Under-Voltage, Over-
Voltage, Breaker Failure).
Optional Relays: 3–4
Approx. Cost: ₹110,000/CT.
Total Cost = 5x₹ 50,000= INR 250,000
d. Vacuum Circuit Breaker (VCB)
Rating: 6.6 kV, 1250A, 40 kA.
Approx. Cost: ₹630,000
e. Feeder Connections
Copper Cables/Busbars as per CT rating:
Estimated Weight = 50 kg.
Cost = 50 kg × ₹850 = ₹42,500
f. Insulators and Accessories
Insulators, spacers, terminal blocks: Approx. ₹15,000
g. Relays, Control Meters, and Wiring
Energy meters and other instruments: ₹25,000
Wiring, connectors, etc.: ₹10,000
2. Labor Cost
Fabrication: ₹10,000
Busbar Machining: ₹5,000
Component Installation and Wiring: ₹15,000
Total Labor Cost: ₹30,000
3. Design and Engineering Cost
Electrical and mechanical design: ₹25,000
4. Testing and Quality Assurance
Type tests, insulation resistance tests, functional tests, etc.: ₹20,000/Panel= ₹ 60,000
5. Overheads
Transportation: ₹15,000+₹5,000
6. Total Cost Summary
Cost Component Estimated Cost (INR)
Panel Structure ₹ 25,120
Copper Busbar ₹ 1,16,145
Heat Shrinkable Sleeves ₹ 3,000
Current Transformers ₹ 3,30,000
Vacuum Circuit Breaker (VCB) ₹ 3,50,000
Feeder Connections ₹ 42,500
Insulators and Accessories ₹ 15,000
Relays and Meters ₹ 3,00,000
Wiring and Connectors ₹ 10,000
Labour ₹ 30,000
Design and Engineering ₹ 25,000
Testing and Quality Assurance ₹ 60,000
Overheads (Transport, GST) ₹ 20,000
Total Estimated Cost ₹ 13,26,765
Total 3 I/C= GRAND TOTAL= ₹ 39,80,298
For Transformer Panel
Key BOM Differences
Component Transformer Feeder Panel Incomer Panel
Main Protection Relay Differential relay, overcurrent, and earth fault relays. Overcurrent, earth fault, under/over-voltage.
Additional Equipment Tap changer controls, cooling controls, surge arrestors. Energy meters, busbar distribution.
Hence Bom is same only minor difference in price for ₹ 78,345= ₹ 12,48,420
TOTAL PANEL: ₹ 52,28,718
ICOG MODIFICATIONx2( market
₹ 3,60,000
information)
SPARE 6.6KV, WITH
₹ 4,92,000
TROLLEY( PO placed prices )
2 YEARS SPARES ( rough
₹ 1,00,000
estimate)
INSTALLATION,TESTING
COMMISSIONING ( Standard ₹ 1,92,000
market rates collected)
TOTAL ₹ 11,44,000
Grand TOTAL= ₹ 6372718
Packing: 1.5% Thumb rule industry standard: ₹ 95590
Transportation: ₹ 150,000 ( 40” container dedicated vehicle)
Sub Total: ₹ 66,18,308
Profit Margin 3%: ₹1,11,881
LANDED Estimate: ₹ 68,09,489
