Solar Water Heaters in Nepal (SKAT, 1979, 142 p.) PART IV EXAMPLES OF COST CALCULATION 7. EXAMPLES OF COST CALCULATION

Solar Water Heaters in Nepal (SKAT, 1979, 142 p.)

PART IV EXAMPLES OF COST CALCULATION

7. EXAMPLES OF COST CALCULATION

7.1 SOLAR SYSTEM

One hotwater storage tank 100ltr.

Two solar collectors SC-85

Pos.	Article	Qty.	Rate	Amount
	Summary material
1-8	Material cost for hot water storage tank 100 Itr. net	1
10-13	Material cost for two solar collectors SC-85 and accessories, net	2
	Sub total
	Summary working hrs., labour charge
1-8	Hotwater storage tank 100 Itr. working hrs., and labour cost	163 hrs.
10-13	Two solar collector SC-85 and accessories
	Working hrs., and labour cost	173 hrs.
	Sub total
	Overhead on material %
	Overhead on labour charge %
	Transportation charge
1-13	Total cost of one solar system one hotwater storage tank 100 Itr. two solar collectros SC-85

7.2 HOTWATER STORAGE TANK 100 LTR.

Pos.	Article		Qty.	Rate	Amount
1	MS-tank 100 ltr. (inside)
1.1	Cylinder MS-sheet 3 mm
	1277 x 800 mm
	1.021 m²+ 10%*		1.23 m²
1.2	Disk up/down MS-sheet 3 mm
	400 x 400 mm
	0.16 m² + 10% = 1.76 m² x 2		0.352 m²
1.3	G.l. pipe (vent)	1/2"	0.1 m
1.4	G.l. hexagon nuts	1/2"	2 pcs.
1.5	G.l. socket	1/2"	1 pc.
1.6	G.l. cap	1/2"	1 pc.
1.7	Red. Socket	1 /2" -3/8"	1 pc.
1.8	Welding rods 0 3 mm		40 pcs.
1.9	Tar-paint (2-coats)		1.2 Itr.
1.10	Cement (inside lining, corrosion production)		5 kg
1.11	Electric charge
1.12	Tool and machine charge
1	Material cost for MS-tank 100 ltr. net
1	Working hrs. and Labour charge for
	cutting, rolling, welding, pressure
	testing, painting and cement coating		24 hrs.
2	Flange with water and solar connection
2.1	Flangeringg MS	10 mm
	outside Ø 220, inside Ø 155		4.25 kg
2.2	Flange MS 10 mm	Ø220 mm	4.25 kg
2.3	Flange pipe MS-sheet 3 mm
	471 x 90 mm = 0.042 m² + 10%		0.046 m²
2.4	G.l. pipe (hot water)	3/4"	0.2 m
2.5	G.l. pipe (hot water)	3/4"	0.712 m
2.6	G.l. pipe (cold water)	3/4"	0.1 m
2.7	G.l. pipe (solar inlet warm)	1 "	0.53 m
2.8	G.l. pipe (solar outlet cold)	1 "	0.1 m
2.9	Baffle plate G.l. sheet 18 gauge
	60 x 70 mm		0.0046 m²
2.10	G.I. elbows	3/4"	2 pcs.
2.11	G .I. elbows	1 "	2 pcs.
2.12	G.I. unions	3/4"	2 pcs.
2.13	G.I. unions	1 "	2 pcs.
2.14	Nipple 2 x 120 mm	3/4"	0.24 m
2.15	Nipple 2 x 100 mm	1 "	0.2 m
2.16	G.I. socket	3/4"	1 pc.
2.17	Steam packing washers for union	¾”	2 pcs.
2.18	Steam packing washers for union	1"	2 pcs.
2.19	Steam packing washer 3 mm
	Ø 180 outside, Ø 145 inside
	Ø 180 mm² = 0.032 m² + 10%		0.035 m²
2.20	Hexagon screws, galv.	M8 x 40	12 pcs.
2.21	Hexagon nuts, galv.	M8	12 pcs.
2.22	Threaded rod, galv. L= 100 mm	M8	1 pc.
2.23	Washers, galv.	M8	12 pcs.
2.24	Red oxyde paint		0.1 ltr.
2.25	Welding rods 0 3 mm	5 pcs.
2.26	Electric charge
2.27	Tool and machine charge
2.28	Oxygen and gas
2	Material cost for flange with water and solar connection, net
2	Working furs. and labour charge for gas cutting, filing, drilling, preparation of pipes, welding and assembling		32 hrs.
3	Side flange for thermostat and electro heating element
3.1	Flangeringg MS 10 mm
	Ø 220 outside, 0 155 mm inside		4.25 kg
3.2	Flange, MS 10 mm 0 220 mm		4.25 kg
3.3	Flange pipe, MS-sheet 3 mm
	0 150 mm, length 90 mm
	471 x 115 mm
	0.054 m² + 10%		0.059 m²
3.4	G.l. pipe	1½ ''	0.42 m
3.5	Disk MS-sheet 3 mm
	48 x 48 mm		0.002 m²
3.6	MS-pipe	1/4"	0.42 m
3.7	Connectorr sheet 2 mm
	60 x 40 mm		0.0024 m²
3.8	Electro element holder 2 mm
	58 x 10 mm		0.0006 m²
3.9	Slotted pan head screw	M6 x 5	1 pc.
3.10	Steam packing washer 3 mm
	Ø 180 outside, 0 145 inside
	Ø 180 mm² = 0.034 m² + 10%		0.038 m²
3.11	Threaded rod + nut	M8 x 100	1
3.12	Hexagon screws, galv.	M8 x 40	12 pcs.
3.13	Hexagon nuts, galv.	M8	12 pcs.
3.14	Washers, galv.	M8	12 pcs.
3.15	Welding rod Ø 3 mm		5 pcs.
3.16	Electric charge
3.17	Tool and machine charge
3.18	Oxygen and gas
3.19	Red oxyde paint		0.1 ltr.
3	Material cost for one side flange for thermostat and electro
	heating element, net
3	Working furs. and labour charge for gas cutting, filing, drilling,
	preparation of pipes, welding and assembling		24 hrs.
4	Insulationn 100 mm (for tank 100 ltr.)
4.1	Fibreglasss insulation 50 mm
	First layer
	1550 x 800		1.24 m²
4.2	Second layer
	1900 x 800		1.52 m²
4.3	Top and bottom
	600 x 600 = 0.36 m² x 4		1.44 m²
4.4	Pe-bag 1900 x 1000 mm		1
4	Material cost for insulation 100 mm thick for one 100 ltr. hotwater storage tank, net
4	Working furs. and labour charge for
	cutting, fixing of the insulation		8 hrs.
5	Outside cover, (for tank 100 ltr.)
5.1	Alu. cover up, prefabricated
	Ø 600 mm.		1 pc.
5.2	Alu. cover down, prefabricated
	Ø 600 mm		1 pc.
5.3	Alu. cover for side flange
	(250 mm), prefabricated Ø 10"		1 pc.
5.4	Alu. cover for bottom flange
	(230 mm), prefabricated 0 9"		1 pc.
5.5	Washers, galv.	M8	2 pcs.
5.6	Hexagon nuts	M8	2 pcs.
5.7	G.l. sheet, cylinder 24 gauge
	1903 x 780 mm
	1.48 m² + 10%		1.59 m²
5.8	Cover belts, G.l. sheet 24 gauge
	(2 pieces)
	50 x 1910 mm
	0.095 m² + 10% = 0.1 x 2		0.2 m²
5.9	Screw plates, 4 pieces
	size: 50x20 x 3 mm
	MS-flat 0.08 m (1.8 kg/m)		0.094 kg
5.10	Hexagon screws, galv.	M8 x 25	4 pcs.
5.11	Hexagon nuts, galv.	M8	4 pcs.
5.12	Washers, galv.	M8	4 pcs.
5.13	Nameplate alu.	190 x 70 mm	1 pc.
5.14	Soldering mat. Tin	40/60	0.05 kg
5.15	Pop rivets alu.	Ø 3	30 pcs.
5.16	G. I. sheet watershild 20 gauge
	400 x 40 mm
	0.016 + 10%		0.017 m²
5.17	Red oxide paint		1.5 ltr.
5.18	White paint,enamel		1.0 ltr
5.19	Blue paint,enamel		0.2 ltr
5.20	Thiner		1.0 ltr
5.21	Tool and machine charge
5.22	Electric charge/gas
5	Material cost for G. l. outside
	cover for one hotwater storage
	tank 100 ltr., net
5	Working furs. and labour charge for
	cutting, of alu. covers and G.l.
	sheets, folding, bending,
	assembling and painting		35 hrs.
6	Electric heating/thermostat
6.1	Heating element removable
	L = 280 mm, Ø 37 mm, 230 V		1 pc.
6.2	Thermostaat, L = 280 mm, Ø 8 mm
	230 V, 20 A
	range 30 -80°C		1 pc.
6.3	Connectorr		1 pc.
6.4	Control lamp		1 pc.
6.5	Wiring		1
6.6	Cable shoes		3 pcs.
6.7	Slotted pan head screws	M4 x 20	3 pcs.
6	Material coast for electro
	heating/thermostat ,net
6	Working furs. and labour charge for
	fixing of heating element, thermostat,
	wiring and testing		5 hrs.
7	Boiler stand SE 100 ltr.
7.1	Belt for boiler stand, MS 3 mm
	1305 x 115 mm
	0.15 m² + 10%		0.165 m²
7.2	G.l. pipe, support legs (3 pcs.) 1"
	length 1000 mm x 3		3 m
7.3	G.l. pipe, support nipples
	(3 pcs.) 1 "
	length 250 mm x 3		0.75 m
7.4	Baseplate MS-sheet		5 mm
	100 x 100 mm
	0.01 m²+ 10%	0.011 m²
7.5	Gl-socketss	1"	3 pcs.
7.6	Hexagon screws, galv.	M10 x 50mm	2 pcs
7.7	Hexagon nuts, galv.	M10	2 pcs.
7.8	Washers, galv	M10	2 pcs
7.9	Welding rods Ø 3 mm		3 pcs
7.10	Red oxyde paint		0.3 ltr.
7.11	Electric charge
7.12	Tool and machine charge
7	Material cost for one boiler
	stand, net
7	Working furs. and labour charge for
	cutting, drilling, rolling, thread
	cutting, welding, painting, and assembling		14 hrs.
8	Wall-hangeers 100 ltr.
8.1	Belt for boiler wall-hangers
	MS 3 mm (2 pcs.)
	1305 x 115 mm
	0.15 ²2 + 10% x 2		0.33 m²
8.2	Insulatingg strip, tarfelt
	1265 x 115 mm (up only)		0.145 m²
8.3	Reinforceement up, MS-sheet 3 mm
	95 x 55 mm (2 pcs.)
	0.0052 m² + 10% x 2		0.002 m²
8.4	Reinforceement down, MS-sheet 3 mm
	95 x 55 mm (2 pcs.)
	0.0052 m² + 10% x 2		0.002 m²
8.5	Hexagon screws, galv.	M10 x 50 mm	4 pcs.
8.6	Hexagon nuts, galv.	M10	4 pcs.
8.7	Washers, galv.	M10	8 pcs.
8.8	Spacing sheets, MS 3 mm
	220 x 195 mm (2 pcs.)
	0.043 + 10% x 2		0.094 m²
8.9	Hangers, MS-flat
	410 x 50 x 5 mm (2 pcs.)
	L = 0.41 m (1.96 kg/m)		0.8 kg
8.10	Wall plugs, Mod. Fischer S12
	(plastic dowel 0 12 mm)		4 pcs.
8.11	Square head wood screws, galv.
	100 x 10 mm, (4" x 3/8")		4 pcs.
8.12	Welding rods 0 3 mm		3 pcs.
8.13	Red oxyde paint		0. 3 ltr.
8.14	Electric charge
8.15	Tool and machine charge
8	Material cost for two wall hangers
	net
8	Working furs. and labour charge for
	cutting, drilling, rolling, welding,
	painting and assembling		21 hrs.

7.3 Hotwater storage tank 100 Itr.,SUMMARY

Pos.	Article	Qty.	Rate	Amount
	Summary Material
1.	MS-tank 100 ltr. (inside)	1
2.	Flange with water and solar connection	1
3.	Side flange for thermostat and electro heating element	1
4.	Insulation, 100 mm (tank 100 ltr.)	1
5.	Outside cover (tank 100 ltr.)	1
6.	Electro heating/thermostat	1
7.	Boiler stand	1
8.	Wall hangers (optional to boiler stand)		1
1-8	Material cost for hotwater storage tank 100 ltr. net
	Working hrs., labour charge
1.	MS-tank 100 ltr. (inside)	24 hrs.
2.	Flange with water and solar connection	32 hrs.
3.	Side flange for thermostat and
	electro heating element	24 hrs.
4.	Insulation 100 mm (tank 100 ltr.)	8 hrs.
5.	Outside cover (tank 100 ltr.)	35 hrs.
6.	Electro heating/thermostat	5 hrs.
7.	Boiler stand	14 hrs.
8.	Wall hangers (optional to boiler stand)	21 hrs.
1-8	Working hrs., labour charge total
	Overhead on materials, %
	Overhead on labour charge, %
	Transportation charge
	Total cost of one hotwater storage tank 100 ltr.

EXAMPLES OF COST CALCULATION

7.4 SOLAR COLLECTOR SC-85

Pos.	Article		Oty.	Rate	Amount
10	Solar collector SC-85
	Size: 1810x 790x 110 mm,
	effective area 1.2 m²
	Weight: 47 kg
10.1	Collector box 24 gauge G. l. sheet
	1000 x 2000 mm
	2m² + 10%*		2.2 m²
10.2	Frame left 24 gauge G. l. sheet
	1829 x 100 mm
	0.182 m² + 10%		0.2 m²
10.3	Frame right 24 gauge G. l. sheet
	1829 x 100 mm
	0.182 m² + 10%		0.2 m²
10.4	Frame top 24 gauge G. l. sheet
	782 x 100 mm
	0.078 m² + 10%		0.086m²
10.5	Frame bottom	24 gauge G. l. sheet
	782 x 150 mm
	1.17 m² + 10%	1.3 m²
10.6	Hexagon head tapping
	screws w. metal and rubber
	washer 6.5 x 16		10 pcs.
10.7	G.l. pipes 1/2"
	length = 1668 mm,	9 pcs.	15.012 m
10.8	G.I. pipes 1 /2"
	length = 830 mm,	2 pcs.	1.66 m
10.9	Alu. fins 26 gauge Alu. sheet
	412 x 120 mm 36 pcs.
	1.78 m² + 10%		1.95 m²
10.10	Cresent rings 27.7 x 21.7 mm		72 pcs.
10.11	Insulation fibreglass	50 mm
	1950 x 1000 mm
	1.95 m²		2 m²
10.12	Glass, 4 mm thick
	1800 x 772 mm		1.39 m²
10.13	Rubberseal,
	U-channel		5.3 m
10.14	Pop-rivets copper Ø 3.2		8 pcs.
10.15	Soldering mat. tin 40/60		0.05 kg
10.16	Black board paint		0.5 ltr.
10.17	Red oxyde		1.0 ltr.
10.18	Brown No. 403 or dark green No. 212
	enamel paint		1.0 ltr.
10.19	Thinner		0.5 ltr.
10.20	Tool and machine charge
10.21	Electric charge
10	Mat. cost for one collector
	type SC-85, net
10	Working hrs., and labour charge
	for one collector type SC-85
	marking, cutting, folding,
	pressing, welding, soldering,
	testing, painting and assembling.		53 hrs.
11	Support for two collectors SC-85
11.1	Hat rails, (G.l. sheets 20 gauge
	1926 x 152 mm (3 pcs. )
	0.292 m² + 10% = 0.32 x 3		1.0 m²
11.2	Hat rails, G.l. sheets 20 gauge
	1638 x,52 mm (2 pcs.)
	0.248 m² + 10% = 0.273 x 2		0.55 m²
11.3	Distance pipes (6 pcs.)
	G.l. pipe 3/4"
	L= 60 mm x 6		0.36 m
11.4	Hexagon screws, galv.	M8 x 70	6 pcs.
11.5	Hexagon nuts, galv.	M8	6 pcs.
11.6	Washers, galv.	M8	12 pcs.
11.7	Flat iron (2 pcs.)
	size: 50 x 150 x 5 mm
	MS-flat 0.3 m (1.96 kg/m)		0.6 kg
11.8	Support sheets	3 mm
	100 x 170 mm	(2 pcs.)
	0.017 m² + 10%		0.019 m²
11.9	Reinforcement triangle sheet, 3 mm
	50 x 50 mm (2 pcs.)
0.25	m² + 10%		0.0027m²
11.10	Hexagon screws, galv.	M8 x 20	4 pcs.
11.11	Hexagon nuts, galv.	M8	4 pcs.
11.12	Washers, galv.	M8	4 pcs.
11.13	G.I. pipes	(2 pcs.)
	L = 600 mm	3/4"	1.2 m
11.14	G.l. pipes	(2 pcs.)
	L = 170 mm	3/4"	0.34 m
11.15	G.I. sockets	3/4"	2 pcs.
11.16	Hexagon screws, galv.	M8 x 20	4 pcs.
11.17	Hexagon nuts, galv.	M8	4 pcs.
11.18	Washers, galv.	M8	4 pcs.
11.19	Red oxyde paint		0.2 llr.
11.20	Dark brown paint		0.2 ltr.
11.21	Tool and machine charge
11.22	Electric charge
11	Mat. cost support for two
	collectors SC-85
11	Working hrs., and labour charge
	support for two collectors SC-85
	marking, cutting, punching,
	folding, thread cutting, painting
	and assembling		42 hrs.
12	Circulation G.l. pipes for two
	collectors SC-85
12.1	G.I. pipe 1742 mm 1 "		1.742 m
12.2	G.l. pipes(2 pcs.)
	L = 787 mm 1 "		1.574 m
12.3	G.I.pipes (2 pcs.)
	L= 150 mm 1"		0.3 m
12.4	G.I. pipes 58 mm 1 "		0.058
12.5	G.l. elbows 1 "		6 pcs.
12.6	G.l. unions 1"		2 pcs.
12.7	Steam packing washers for
	union 1"		2 pcs.
12.8	G.l. caps 1 "		2 pcs.
12.9	Fibreglass insulation 50 mm 1.0 m²
12.10	Red oxyde paint		0.3 ltr.
12.11	Tool and machine charge
12	Mat. cost circulation pipes for
	two collectors SC-85
12	Working hrs., and labour charge,
	circulation pipes for two
	collectors SC-85
	marking, cutting, thread cutting,
	painting and assembling		14 hrs.
13	Panels for two collectors SC-85
13.1	Middle panel 24 gauge
	1840 x 200 mm
0.368	m² + 10%		0.4 m²
13.2	Side panel 24 gauge
	1950 x 265 mm (2 pcs.)
	0.516 m² + 10% x 2		1.14 m²
13.3	Top panel 24 gauge
	2018 x 265 mm
	0.534 m² + 10%		0.59 m²
13.4	Pan head tapping screws, galv. 3.5 x 95		8 pcs
13.5	Red oxyde paint		1.0 ltr.
13.6	Dark brown paint.		1.0 ltr.
13.7 ´	Tool and machine charge
13	Mat. cost panels for two
	collectors SC-85
13	Working hrs., and labour
	charge panels for two collectors
	marking, cutting, folding, drilling
	painting, assembling		11 hrs.

7.5 SOLAR COLLECTOR SC-85, SUMMARY

Pos.	Article	Qty.	Rate	Amount
	Summary Material
10	Material cost for two collectors SC-35	1 set
11	Support for two collectors SC-85	1
12	Circulation G. I. pipes for two
	collectors SC-85	1
13	Panels for two collectors SC-35	1
10-13	Material cost for two solar collectors
	SC-85 and accessories, net
	Working hrs., labour charge
10	Solar collector SC-85
	two pieces (2 x 53 hrs.)	106 hrs.
11	Support for two collectors SC-85	42 hrs.
12	Circulation G. I. pipes for two
	collectors SC-85	14 hrs.
13	Panels for two collectors SC-85	11 hrs.
10-13	Working hrs., labour charge total	173 hrs.
	Overhead on materials, %
	Overhead on labour charge %
	Transportation charge
	Total cost for two solor collectors SC-85
	and accessories