ELECTRICAL ESTIMATION AND

COSTING

Module 5
 Substations
• INDOOR SUBSTATION
1. Substations of the integrally built type
2. Substation of the composite built-up type
3. Unit type factory fabricated substations and metal
clad switch boards
• OUTDOOR SUBSTATION
1. Pole mounted substation
2. Foundation mounted substation
 Selection and location of Site
• Type of Substation
• Availability of land
• Communication facility
• Atmospheric pollution
• Availability of essential amenities to the staff
Indoor Substation- Layout
Indoor Substation- Single Line Diagram
Out-door Or Pole Mounted Substation
33kV Substation
220/11KV Substation
Substation auxiliaries supply
 Earth Mesh

Earthing Electrodes
Substation
Earthing Earthing risers

Earthing connection
 Problem 1
• A 37KW connection is to be given to an agriculture
field at 415 V, 3 Phase 50Hz. The connection is to be
given from a 3 phase 11 kV OH line which is available
at a distance of 40M. The motor has a full load
efficiency of 85% and power factor of 0.8.
• Load (O/P)= 37kW
• Load (i/p) = (37/0.85) = 43.53kW
• Load KVA = KW/pf = 43.53/0.8 = 54.411kVA
• Primary Side current = (54.41*1000)/Sq.rt of 3* Vp) = 2.855
• Secondary side current = (54.41*1000/Sq.rt of 3 *Vs) = 75.695

• 63KVA, 11/0.433kV Delta to Start connected 3 Phase transformer.

• Al Armoured cable 3 ½ core, 25mm2 cable b/w transformer and the
agricultural motor room.
• ACSR 6/1 *2.11 conductor, b/w the transformer and OH line.

• Length of cables

• ACSR conductor= 3*30+ 3*1(Wastage)+4*3(till the transformer)=

93m+12m=105m
• AI Armourd cable= 6+10+3+1+1 = 21m
Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

HT Connection
1 MS Channel 1 300 300
100mm*50mm*7.5mm*
1.5m
2 ACSR 6/1 *2.11 93m or 9.3kg 160/kg 10m = 1kg
conductor
3 GI Wire 7/16 SWG 30+1=31= 270/kg
3.1KG
4 Disc type insulator 3 960 2880
5 Pin type insulator 3 300 900
6 Stay Set complete in all 1 2100 2100
aspects
7 Earth wire clamp 1 60 60
8 T clamp for MS Channel 1 600 600
Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

Pole Mounted Substation

9 RS Joists 2 7500 15000
175mm*100mm*11m
long
10 11kV Lightning arresters 3 or 1 set 2000/each or 6000
6000/set
12 Disc insulator 3 960
13 GO Switch( Air break 1 7500 7500
triple pole switch) with
operating pipe and handle
14 Expulsion type fuse 11kV
installed with insulators
Insulators 3 960 2880
Fuses 3 800 2400

MS Angle (2m each) 3 150 450

15 MS Angle 2 900 1800 Distance b/w the

10mm*50mm*6mm*2m two poles where
the transformer is
places is 2m
Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

19 PG Clamps 3 150 450

20 PG Bimetallic clamps 3 150 450

21 Al Armoured cable 3 ½ core, 3m 200 600 LT side of the

25mm2 cable transformer
22 GI pipe 3 250 750

23 GI bend 2 75 150

24 Earthing set with plate 2 5500 11000

earthing
25 Stay rod set 2 2100 4200
26 Stay insulator 2 100 200
27 Binding Wires 0.5kg 270/kg 135

28 Danger plate 1 100

29 Number plate 1 100

30 Barbed Wires 5kg 50 250

31 Nuts and bolts 200

32 Concreating 2 1000 2000

Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

Service Connection
33 Al Armoured cable 3 ½ core, 21m 200 4200
25mm2 cable
34 LT cable box indoor type with 1 500 500
all fittings
35 LT cable box for Outdoor 1 600 600
type
36 IC Cutouts fitted with fuse 1 set 750 750
and all the fittings
37 Meter box

25*30cm 1 400 400

45*60cm 1 1000 1000

38 Energy meter

3 Phase 1 3000 3000

1 PHASE 1 1200 1200
39 8 SWG GI Wire 21 or 2.1kg 300/kg 630

40 Nuts and bolts 150

41 Sand and Bricks 2000

Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

Total 238463

Storage and Transportation (5%) 11923

Labour Charge (10%) 23846

Contingency (1%) 2384

Electrical inspection charge 3000

Grand Total 279617

 Problem 2
• Electric supply to a factory is taken from an
11kV overhead, 3 phase which is terminated at
2 pole structure at a distance of 20m from the
main board of the factory. The supply is to be
given through a 11/0.433kV transformer and
the factory has a load of 80 kVA. Estimate the
quantity of materials required and the total cost
 Problem 3
• Estimate the quantity of materials and cost for
erection of a 250KVA pole mounted substation.
– Primary current = 250*1000/(sq.rt of 3 * 11000)
= 13.12A = ACSR conductor 7/2.11mm
– Secondary Current = 250*1000/(sq.rt of 3 * 415)
= 61/2.6mm, 1100V PVC cable
 Problem 4
• Prepare the list of material required and
calculate the cost of installation of a 400kVA
indoor type 11/0.433kV transformer.
Sl No Description of the material with full Quantity Rate Amount Remarks
specification required

1 400kVA, 11/0.433kV 3 Phase 1 400000 400000

transformer complete with all the
accessories.
2 XLPE insulated Al conductor 30m 800/m 32000
10mm2, 3 core 11kV cable
3 11kV outdoor terminal box 1 2700 2700
4 11kV indoor terminal box 1 1800 1800
5 GI pipe 76mm diameter heavy 5m 300/m 1500
gauge
6 Clamps for fixing cable pipe 10 no 80/each 800
7 Indoor type Oil CB, 11kV with 1 150000 150000
50/5 CT & accessories
8 Earthing of OCB 2 5200/earthi 10400
ng
9 Sand 5000
10 Bricks 15000 Trench
11 Slabs 100 nos 1600/each` 160000
Sl No Description of the material with full Quantity Rate Amount Remarks
specification required

12 Empire tape 20 rolls 120 2400

13 HT tape 3 180 540
14 Foundation of Transformer 1 6000 6000

15 Earthing of Transformer 2 5200 10400

16 OCB FOR 415V 800A, 500/5 A 1 75000 75000
CT
Overload trip coil
17 LT cubicle board with locking 1 125000 125000
arrangement
18 LT Cable 3 ½ core 30m 1200/m 36000
19 Aluminum Lugs 16 300 4800
20 Earthing of LT panel 2 5200 10400
21 Fire extinguisher 1 10000
22 Shock treatment chart 1 200
23 First Aid box 1 1000
24 Miscellaneous 15000
Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

Total

Storage and Transportation (5%)

Labour Charge (10%)

Contingency (1%)

Electrical inspection charge 3000

Grand Total
 Problem 5
• Estimate the quantity of materials and cost for
installation of10 MVA, 33/11KV substation
33kV Substation
• Instead of one 10 MVA transformer we will be
using two 5 MVA transformer.
Full load current at 33kV side
= 5000000/(sq.rt 3*33000)=87.5A
Full load current at 11kV side
=5000000/sq.rt 3 *11000)=262.5A
Sl No Description of the material with full Quantity Rate Amount Remarks
specification required

1 5MVA, 33/11kV transformer with all 2 400000 800000

fillings and accessories
2 33kV GO switch complete all the 3 75000 225000
structure
3 33kV Lightning arrestors 1 set of 3 5000 5000
4 Power factor correction device 11kV 2 130000 260000
shunt type (Capacitive banks)
5 4 SWG hard drawn copper conductor 100m= 400 40000 33kV line to
100 kg Bus bar
6 6 SWG hard drawn copper conductor 200m= 400 40000 33kV Bus bar
100kg to Transformer
7 11kV 3 core XLPE 240mm2 Al 50 3000 150000 Transformer to
conductor armoured cable Panel
8 Cable box, 33 kV, 3 core 4 1500 6000
9 Cable box, 11kV 4 1000 4000
10 11kV, 3 Phase, 50Hz metal clad switch
board
OCB 400A, complete with CT and PT 8 or 2 set 200000 1600000
of 4
Sl No Description of the material with full Quantity Rate Amount Remarks
specification required

11 Transformer platform 2 25000 50000

12 Cable trench 35m 600
13 Substation structure for GO switch, 2 sets 38000 76000
Isolators, breakers
14 33kV OCB 3 300000 900000 1 incoming 2
towards
transformer
15 Control Cables 1.5mm2 copper cable 50m 500/m 25000
16 Earthing 26 5500 4
(transformer)+6(3
33kV panels)+ 16
(8 11kV panels)
17 Empire tape 30 rools 150
18 HT tape 10 180
19 Jointing materials 16 600 8 outgoing lines
20 Miscellaneous 15000
Sl No Description of the material Quantity required Rate Amount Remarks
with full specification

Total

Storage and Transportation (5%)

Labour Charge (10%)

Contingency (1%)

Electrical inspection charge 3000

Grand Total
 Problem 6
• Estimate the quantity of materials required
and cost of installation of 132/33kV substation
with main and transfer bus scheme having
2*40 MVA transformer.
Sl No Description of the Quantity required Rate (Lakhs) Amoun Remarks
material with full t
specification (Lakhs)

1 CB
132 kV 6 8.15 5+1(Bus Coupler)
33kV 10 2.3 9+1(Station
transformer)
2 Isolators
132kV 17 0.62 3*5+2
33kV 18 0.34 7*2+2*1+1+1
3 CTs
132 5*3 Phase =15 1
33 9*3 Phase =27 0.25
4 CVT
132kV 3*3 Phase +1 Bus bar = 10 0.95
33kV 2 0.2
5 LA
132 5 0.35
Sl No Description of the material Quantity required Rate (Lakhs) Amoun Remarks
with full specification t
(Lakhs)

6 Post Insulators 90 0.09 (Aproxima)

7 Transformer
132/33kV 2 275 550
33/0.433kV 1 3.75

8 Control Panel
Control and relay panel 2 4.86
B/C panel 1 0.91
Double feeder panel 1 1.62
Distance protection panel 2 4.62
33kV triple feeder panel 3 2.5
9 Relay panel 1 5
10 Energy Meter 1 5.42
11 Control and Power cables 25
12 Structures 30
13 DC Equipment 3.5
Sl No Description of the material Quantity required Rate (Lakhs) Amoun Remarks
with full specification t
(Lakhs)

14 Bus bar and insulators 10

15 lighting on the control 12
room
16 Earthing mat and Earthing 30
17 Firefighting equipment 4

18 Boundary wall, Fencing, 100

Control room building
19 Land 40
Total
Spare 3%
Civil Wrk 5%
Transportation 5%
Supervision charges 25%
Erection 7.5%
Contingency 3%
T&P 1.5%
Grand Total
 Assignment
• Estimate the quantity of materials required for
the augmentation of 33 kV grid substation of
500KVA to 1000 kVA, 33/11kV grid substation.