1. Report On
TRANSFORMER
PRODUCTION COST
Supervised by
Md. Azimussan Abbasi
Production In-Charge
Manager, Energypac Engineering Ltd.
Abhi Dutta
Assistant Engineer (Paint & Project)
Energypac Engineering Ltd.
Prepared by
Jahirul Islam (201318019)
Muhammad Momotazul Islam (201318045)
Suvro Bhowmick (201318050)
Tousif Islam (201318052)
Jabid Ishtiaque (201218035)
Department of Mechanical Engineering
Military Institute of Science &
Technology (MIST)

2. 1
Table of Contents
CONTENTS ........................................................................................................................... PAGE NO
Introduction.................................................................................................................................................. 3
55 MVA ......................................................................................................................................................... 4
Tank assembly........................................................................................................................................... 5
CT-PT ...................................................................................................................................................... 12
Radiator .................................................................................................................................................. 13
Paint ....................................................................................................................................................... 13
Manpower............................................................................................................................................... 15
Manufacturing overhead ........................................................................................................................ 15
120MVA...................................................................................................................................................... 17
Tank assembly......................................................................................................................................... 17
CT-PT ....................................................................................................................................................... 26
Radiator................................................................................................................................................... 26
Paint ........................................................................................................................................................ 27
Manpower............................................................................................................................................... 28
Manufacturing overhead ........................................................................................................................ 29
Price list of Power Transformers................................................................................................................ 31
Conclusion................................................................................................................................................... 31

3. 2
Introduction
We recently have done our industrial training in Energypac Engineering Ltd. The industrial training basically
revolved around the transformer tank design, Conservator tank, CT & PT, painting and assembling of the total
transformer tank.
Energypac is one of the leading power engineering companies in Bangladesh. Continual research and
development, state of the art production facility, quality products, competent services, and countrywide
operations have made it warmly acceptable to the customers.
Energypac has many ventures of products and utilities but their main product is Transformers. A transformer is an
electrical device that transfers electrical energy between two or more circuits through electromagnetic induction.
Electromagnetic induction produces an electromotive force across a conductor which is exposed to time varying
magnetic fields. Commonly, transformers are used to increase or decrease the voltages of alternating current in
electric power applications.
During our training period our assignment was to evaluate the production cost of any given transformer. By the
completion of our training we managed to work on two models of transformers which are:
1. 55MVA
2. 120 MVA
We had to study the designs thoroughly as well as spend hours of data collection in all the production facilities.
The production line is fully run by human workers and thus there were lots of variations in data from section to
section. We had to do some estimation to finally generalize the data.
Sections for Manufacturing Transformer Tank
1.Transformer Tank Section
2. Miscellaneous Section
3. Machine Shop Section
4. Radiator Section
5. CT & PT Tank Section
6. Paint Section
Categories
We divided our evaluation process in some categories to find the accurate result. They are:
1. Direct materials
 Tank section
 Radiator section
 Paint section
 CT-PT section
2. Direct labors
3. Manufacturing overhead
 Electricity cost
 Indirect material cost

4. 3
55MVA
Direct Material Cost: Tank section
In this category we took help from the bills of material and designs. We studied every design and finally
differentiated the product weights and scrap weights.

5. 4
HV SIDE TANK WALL (55MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 HV SIDE PLATE 1260.04 1 1260.04 50 63002 1218.42 41.62 20 832.4 62169.6
2 HANDHOLE FLANGE
DIA 480
8.676667 3 26.03 50 1301.5 24.75 1.28 20 25.6 1275.9
3 STRENGTHEING 20.345 2 40.69 50 2034.5 28.77 11.92 20 238.4 1796.1
4 LIFTING LUG 21.83 2 43.66 50 2183 42 1.66 20 33.2 2149.8
5 ENDPLATE 4.83 2 9.66 50 483 8.68 0.98 20 19.6 463.4
6 RIB AT LIFTING 110.675 2 221.35 50 11067.5 205.38 15.97 20 319.4 10748.1
7 RIB AT LIFTING 110.678 5 553.39 50 27669.5 541.47 11.92 20 238.4 27431.1
8 RIB WITH HOLES 110.675 2 221.35 50 11067.5 216.612 4.738 20 94.76 10972.74
9 RIB AT HYDRAULIC
JACKING PAD
24.835 2 49.67 50 2483.5 49.5 0.17 20 3.4 2480.1
10 HYDRAULIC JACKING
PAD
32.38 2 64.76 50 3238 64.76 0 20 0 3238
11 PIPE FOR
RADIATOR VALVE
0.733333 18 13.2 200 2640 13.2 0 20 0 2640
12 FLANGE FOR
RADIATOR VALVE
4.415556 18 79.48 50 3974 79.48 0 20 0 3974
13 CABLE HOLDER
CLAMP
0.113333 9 1.02 50 51 1.02 0 20 0 51
14 EARTHING PAD M20 0.98 1 0.98 250 245 0.98 20 19.6 225.4
15 EARTHING PLATE M8 0.049167 12 0.59 250 147.5 0.564 0.026 20 0.52 146.98
16 FLUX COLLECTOR 35.79556 9 322.16 240 77318.4 322.16 0 20 0 77318.4
17 FLUX COLLECTOR 27.08333 6 162.5 240 39000 162.5 0 20 0 39000
TOTAL 246080.62

6. 5
LV SIDE TANK WALL (55MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(t
k)
Final
cost(tk)
1 LV SIDE PLATE 1260.04 1 1260.0
4
50 63002 1205.62 54.42 20 1088.
4
61913.6
2 HANDHOLE
FLANGE DIA 480
8.6775 4 34.71 50 1735.5 33 1.71 20 34.2 1701.3
3 STRENGTHENING 20.345 2 40.69 50 2034.5 28.77 11.92 20 238.4 1796.1
4 LIFTING LUG 21.83 2 43.66 50 2183 42 1.66 20 33.2 2149.8
5 ENDPLATE 4.83 2 9.66 50 483 8.68 0.98 20 19.6 463.4
6 RIB AT LIFTING 110.675 2 221.35 50 11067.
5
205.38 15.97 20 319.4 10748.1
7 RIB AT LIFTING 110.68 7 774.76 50 38738 758.072 16.688 20 333.7
6
38404.24
9 RIB AT HYDRAULIC
JACKING PAD
24.835 2 49.67 50 2483.5 49.5 0.17 20 3.4 2480.1
10 HYDRAULIC JACKING
PAD
32.675 2 65.35 50 3267.5 65.35 0 20 0 3267.5
11 PIPE FOR
RADIATOR VALVE
4.415555
6
18 79.48 200 15896 79.48 0 20 0 15896
12 CABLE HOLDER
CLAMP
0.113333
3
9 1.02 50 51 1.02 0 20 6.2 44.8
13 EARTHING PLATE M8 0.98 1 0.98 250 245 0.67 0.31 20 7.52 237.48
14 FLUX COLLECTOR 0.049473
7
19 0.94 240 225.6 0.564 0.376 20 0 225.6
15 FLUX COLLECTOR 35.79571
4
7 250.57 240 60136.
8
250.57 0 20 0 60136.8
16 HOLDER FOR
GAS SAMPLING
DEVICE
29.4375 8 235.5 50 11775 235.5 0 20 0.2 11775
17 PIPE HOLDER 0.21 1 0.21 50 10.5 0.2 0.01 20 0 10.3
18 CONNECTING PLATE 5.13 2 10.26 50 513 10.26 0 20 0 513
TOTAL 211763.1
2

7. 6
RIGHT SIDE TANK WALL (55MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost
(tk)
Final
cost(tk)
1 RIGHT SIDE PLATE 447.52 1 447.52 50 22376 447.126 0.394 20 7.88 22368.12
2 RIB WITH HOLES 110.675 2 221.35 50 11067.5 215.64 5.71 20 114.2 10953.3
3 SUPPORT FOR MDU 2.355 2 4.71 50 235.5 4.7 0.01 20 0.2 235.3
4 SUPPORT FOR MDU 1.08 2 2.16 50 108 2.16 0 20 0 108
5 SUPPORT FOR
MARSHELLING BOX
2.55125 2 5.1025 50 255.125 5.1025 0 20 0 255.125
6 SUPPORT FOR
MARSHELLING BOX
1.12 2 2.24 50 112 2.24 0 20 0 112
7 CABLE HOLDER
CLAMP
0.753333 3 2.26 50 113 2.26 0 20 0 113
8 EARTHING PLATE M8 0.05 2 0.1 250 25 0.1 0 20 0 25
9 FLANGE DN50 PN10
gr.
3.46 1 3.46 50 173 3.22 0.24 20 4.8 168.2
10 VALVE NAME PLATE 0.13 1 0.13 50 6.5 0.13 0 20 0 6.5
TOTAL 34344.55

8. 7
LEFT SIDE TANK WALL (55MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost
(tk)
Final
cost(tk)
1 LEFT SIDE PLATE 448.98 1 448.98 50 22449 448 0.98 20 19.6 22429.4
2 RIB WITH HOLES 110.675 2 221.35 50 11067.5 215.64 5.71 20 114.2 10953.3
3 DN50 OIL
FILLING PIPE
9.51 1 9.51 200 1902 9.51 0 20 0 1902
4 OIL SAMPLING
PIPE
2.68 1 2.68 200 536 2.68 0 20 0 536
5 OIL DRAINING
PIPE DN50
1.12 1 1.12 200 224 0.92 0.2 20 4 220
6 FLANGE
DN50 PN10 gr.
3.46 2 6.92 50 346 6.44 0.48 20 9.6 336.4
7 FLANGE
DN15 PN6 gr.
0.55 1 0.55 50 27.5 0.55 0 20 0 27.5
8 SPACER 0.07 1 0.07 50 3.5 0.07 0 20 0 3.5
9 SPACER 0.16 1 0.16 50 8 0.16 0 20 0 8
10 TRANSPORT OIL
LEVEL GAUGE
1.41 1 1.41 50 70.5 1.321 0.089 20 1.78 68.72
11 SUPPORT FOR
N2 CHECKING
DEVICE
0.4 1 0.4 50 20 0.4 0 20 0 20
12 EARTHING PLATE
M12
0.06 1 0.06 250 15 0.06 0 20 0 15
13 LADDER RUNG 1.778889 9 16.01 200 3202 16.01 0 20 0 3202
14 NAME PLATE 3.81 1 3.81 50 190.5 3.81 0 20 0 190.5
15 VALVE POSITION
PLATE
4.6 1 4.6 50 230 4.6 0 20 0 230
16 CONNECTION
DIAGRAM
PLATE
2.32 1 2.32 50 116 2.32 0 20 0 116
17 VALVE NAME
PLATE
0.133333 3 0.4 50 20 0.4 0 20 0 20
18 FLUX COLLECTOR 35.79667 6 214.78 240 51547.2 214.78 0 20 0 51547.2
TOTAL 91825.52

9. 8
BOTTOM SIDE (55MVA)
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost
(tk)
Final
cost(tk)
1 BOTTOM PLATE 1467.56 1 1467.56 50 73378 1427.593 39.96
7
20 799.3
4
72578.66
2 SLIDING PLATE 225.075 2 450.15 50 22507.5 444.11 6.04 20 120.8 22386.7
3 CHASSIS RIB 9.34125 8 74.73 50 3736.5 72.83 1.9 20 38 3698.5
4 CHASSIS RIB 4.27 4 17.08 50 854 17.08 0 20 0 854
5 CHASSIS RIB 18.015 4 72.06 50 3603 72.06 0 20 0 3603
6 HORIZONTAL
BOX STIFFNER
30.44 2 60.88 50 3044 60.25 0.63 20 12.6 3031.4
7 HORIZONTAL
BOX STIFFNER
50.115 2 100.23 50 5011.5 100.23 0 20 0 5011.5
8 HORIZONTAL
BOX STIFFNER
24.29 2 48.58 50 2429 47.95 0.63 20 12.6 2416.4
9 VERTICAL BOX
STIFFNER
11.65 4 46.6 50 2330 46.6 0 20 0 2330
10 VERTICAL BOX
STIFFNER
11.43 8 91.44 50 4572 88.92 2.52 20 50.4 4521.6
11 THREADED ROD 1.665 4 6.66 250 1665 6.66 0 20 0 1665
12 SQUARE STEEL 0.595 12 7.14 50 357 7.14 0 20 0 357
TOTAL 122453.7
6
TANK FRAME (55MVA)
No. Item name Raw
unit
wt
(kg)
Qty. Total
raw
wt
(kg).
Unit
price(
tk)
Raw
cost(tk
)
Produc
t
wt
(kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(t
k)
Final
cost(tk)
1 FRAME PLATE LONG 133.79
5
2 267.59 50 13379.
5
255.82 11.77 20 235.4 13144.1
2 FRAME PLATE SHORT 46.215 2 92.43 50 4621.5 89.39 3.04 20 60.8 4560.7
3 INNER FRAME
RETAINER
8.79 1 8.79 2000 17580 8.79 0 20 0 17580
4 MIDDLE FRAME
RETAINER
8.98 1 8.98 2000 17960 8.98 0 20 0 17960
5 OUTER FRAME
RETAINER LONG
3.345 2 6.69 2000 13380 6.69 0 20 0 13380
6 OUTER FRAME
RETAINER SHORT
1.295 2 2.59 2000 5180 2.59 0 20 0 5180
TOTAL 71804.8

10. 9
CONSERVATOR (55MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scra
p
cost
(tk)
Final
cost(tk
)
1 CONSERVATOR BODY 476.2 1 476.2 50 23810 476.2 0 20 0 23810
2 CONSERVATOR OLTC
CONSERVATOR SHELL 13.9 1 13.9 50 695 13.3 0.6 20 12 683
RIM 450 DIA 8.2 1 8.2 50 410 8.2 0 20 0 410
BREATHING PIPE 450 1.63 1 1.63 50 81.5 1.5 0.13 20 2.6 78.9
PIPE-END DN25 L=135 0.4 1 0.4 50 20 0.4 0 20 0 20
PIPE END DN25 L=83 0.3 1 0.3 50 15 0.3 0 20 0 15
FLANGE DN25 PN10 1.1 3 3.3 50 165 3.12 0.18 20 3.6 161.4
LIFTING EYE 0.6 1 0.6 50 30 0.53 0.07 20 1.4 28.6
3 CONSERVATOR RIM 18.55 2 37.1 50 1855 37.1 0 20 0 1855
4 END PLATE 1240 DIA
END PLATE 1240 DIA 132.7 1 132.7 50 6635 132.7 0 20 0 6635
LIFTING EYE 0.6 1 0.6 50 30 0.53 0.07 20 1.4 28.6
5 END PLATE WITH FLANGE
MESSKO OLI
END PLATE 113.7 1 113.7 50 5685 113.7 0 20 0 5685
LIFTING EYE 0.6 1 0.6 50 15 0.6 0 20 0 30
6 END PLATE 540 DIA WITH
FLANGE MESSKO OLI
END PLATE 21.4 1 21.4 50 1070 21.4 0 20 0 1070
FLANGE FOR MESSKO
OLI
1.8 1 1.8 50 90 1.8 0 20 0 90
LIFTING EYE 0.6 1 0.6 50 30 0.53 0.07 20 1.4 28.6
7 CONNECTION LEG
LEG 5.6 2 11.2 50 560 11.2 0 20 0 560
RIB 1.05 4 4.2 50 210 3.12 1.08 20 21.6 188.4
CONNECTION PLATE 8.2 1 8.2 50 410 6.56 1.64 20 32.8 377.2
8 CONSEVATOR LEG 23.7 2 47.4 50 2370 46.02 1.38 20 27.6 2342.4
9 CONNECTION PLATE 1.05 2 2.1 50 105 1.56 0.54 20 10.8 94.2
10 PIPE-END DN25 0.3 1 0.3 50 15 0.3 0 20 0 15
11 HANDHOLE FLANGE
WITH THROUGH HOLES
380 DIA
5 1 5 50 250 5 0 20 0 250
12 PIPE-ENDS DN80 0.9 1 0.9 50 45 0.9 0 20 0 45
13 FLANGE DN50 PN10 2.7 1 2.7 50 135 2.7 0 20 0 135
14 PIPE-ENDS DN25 0.3 1 0.3 50 15 0.3 0 20 0 15
15 FLANGE DN25 PN10 1.1 1 1.1 50 55 1.1 0 20 0 55
16 SPACER BOTTOM
SPACER L=2600 1.05 2 2.1 50 105 2.1 0 20 0 105

11. 10
SPACER L=112 0.05 2 0.1 50 5 0.1 0 20 0 5
17 ATMOSEAL
PROTECTOR
0.25 2 0.5 50 25 0.5 0 20 0 25
18 ATMOSEAL FIXING 0.06 2 0.12 50 6 0.12 0 20 0 6
19 PIPE HOLDER L= 150 0.6 1 0.6 50 30 0.55 0.05 20 1 29
20 PIPE HOLDER L = 295 1.2 1 1.2 50 60 1.1 0.1 20 2 58
21 BUILD IN AIR VENT
PLUG
0.11 2 0.22 50 11 0.22 0 20 0 11
22 LIFTING EYE 0.6 2 1.2 50 60 0.5 0.7 20 14 46
23 CABLE HOLDER 100 0.1 1 0.1 50 5 0.07 0.03 20 0.6 4.4
24 CABLE HOLDER 400 0.1875 8 1.5 50 75 1.5 0 20 0 75
25 EARTHING PLATE M8 0.046667 15 0.7 50 35 0.7 0 20 0 35
TOTAL 45105.
7
YOKE CLAMP (55 MVA)
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt (kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt (kg).
Scrap
unit
cost
(tk)
Scrap
cost (tk)
Final
cost(tk)
1 HV & LV TOP
CLAMP
294.7204 4 1178.882 50 58944.08 887.16 291.7216 20 5834.432 53109.65
2 PRESSING PAD
END
3.9575 4 15.83 50 791.5 15.83 0 20 0 791.5
3 PRESSING PAD
MIDDLE
10.77 4 43.08 50 2154 43.08 0 20 0 2154
4 CLAW
SUPPORT
5.495 12 65.94 50 3297 65.94 0 20 0 3297
5 DESCRIPTION 3.675 4 14.7 50 735 12.92 1.78 20 35.6 699.4
6 BRIDGE
SUPPORT
1.025 8 8.2 50 410 8.2 0 20 0 410
7 STOP PIECE 0.518333 12 6.22 50 311 6.22 0 20 0 311
8 SUPPORT
FIXING
BRACKET
0.627895 19 11.93 50 596.5 11.88 0.05 20 1 595.5
9 LIFTING PAD 10.676 4 42.704 50 2135.2 42.704 0 20 0 2135.2
10 RIB 4.01875 8 32.15 50 1607.5 28.6 3.55 20 71 1536.5
11 FOOT
CONNECTION
3.971667 6 23.83 50 1191.5 22.925 0.905 20 18.1 1173.4
12 RIB FOR FOOT 1.468333 6 8.81 50 440.5 8.81 0 20 0 440.5
14 FLITCH PLATE 16.34833 12 196.18 50 9809 196.18 0 20 0 9809
15 CLAMPING
PLATE
2.796667 12 33.56 50 1678 33.56 0 20 0 1678
17 FEET 102.9133 3 308.74 50 15437 308.74 0 20 0 15437
18 CLAW 3.791667 6 22.75 50 1137.5 22.75 0 20 0 1137.5
20 TOP BRIDGE 30.61667 3 91.85 50 4592.5 91.85 0 20 0 4592.5
21 END BRIDGE 47.915 2 95.83 50 4791.5 95.83 0 20 0 4791.5
22 SIDE BRIDGE 6.03 4 24.12 50 1206 24.12 0 20 0 1206
TOTAL 105305.15

12. 11
TANK ASSEMBLY
No. DESCRIPTION QTY TOTAL RAW
WEIGHT(kg)
TOTAL PRODUCT
WEIGHT(kg)
TOTAL
SCRAP(kg)
COST (tk)
1 HV SIDE TANK WALL 1.00 3070.54 2979.276 91.264 246080.6
2 LV SIDE TANK WALL 1.00 3093.21 2988.796 104.414 211763.1
3 RIGHT SIDE TANK WALL 1.00 689.03 682.676 6.354 34344.55
4 LEFT SIDE TANK WALL 1.00 935.13 927.671 7.459 91825.52
5 TANK BOTTOM PLATE 1.00 2156.26 2104.573 51.687 122453.8
6 TANK FRAME 1.00 387.06 372.25 14.81 71804.8
7 CONSERVATOR
SUPPORT,RIGHT
2.00 83.76 83.76 0 4188
8 CONSERVATOR SUPPORT,
LEFT
2.00 99.80 93.8 6.00 4870
9 RIB 4.00 7.91 7.91 0 395.5
10 CONNECTION PLATE 2.00 16.38 15.9923 0.3877 811.246
11 EARTHING PLATE M8 1.00 0.05 0.05 0.00 12.50
12 RIB 4.00 11.98 11.79 0.19 595.2
13 ROPE GUIDE 4.00 16.09 16.09 0.00 804.5
14 ROLLER ASSEMBLY 4.00 1013.17 998.04 521.71 12589.18
15 CONSERVATOR `1.00 1252.3 1245.66 6.64 45105.7
16 YOKE CLAMP 1.00 2225.29 1927.2834 298.0066 105305.1
TOTAL 15057.96 14455.6177 1108.9223 952949.296
Direct Material Cost: Current Transformer-Potential Transformer
132KV
Current Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST(tk)
DIA 550mm 66 250 16500
CT Base 40 50 2000
TOTAL 18500

13. 12
Potential Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST(tk)
MS Sheet 90 50 4500
Oil Chamber 30 50 1500
TOTAL 6000
33KV
Current Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST(tk)
DIA 350mm 31 50 7750
CT Base 13 50 650
TOTAL 8400
Potential Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST(tk)
MS Sheet 31 50 1550
Oil Chamber 11 50 550
TOTAL 2100
Direct Material Cost: RADIATOR section
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST(tk)
Sheet Metal 14928.3 kg 60 tk/kg 895698
Pipe 199.08 ft Scrap=14.256kg 200 tk/ft Scrap=20tk/kg 39530.88
Flange 36 piece 360 tk 12960
Attaching rod & holder 108kg 60 tk/kg 6480
Oil nob 36 piece 120tk 4320
Total = 958988.88
Direct Material Cost: PAINT section
Item name Total painted surface area (m
2
) Total sand blasted surface area(m
2
)
Tank 400 400
CT-PT tank-base-CC 1015 520
CT/PT Doom cover 200 100
Radiator 1411.2 0
CC 15 15
Others 195.27 195.27
Total 3236.47 1230.27

14. 13
Sand (kg)/square meter = 0.854 kg/m2
Sand unit price = 25tk/kg
Sand Cost = 1230.27* 0.854* 25 = 26266.26 tk
Chemical Treatment
Chemical Name Consumed(kg) Cost per Kg (Taka) Total cost (Taka)
Gardo Bond C 30 275 8250
Gardo Len 26 M 6.25 380 2375
Total 10625
BERGER PAINT
PAINT NAME CONSUMPTION (gallon) COST PER GALLON TOTAL COST (tk)
Epoxy Primer 32.5 2621 85182.5
Epoxy Enamel 30 2741 82230
C/A for Primer 16.25 2621 42591.25
C/A for Enamel 15 2741 41115
T-7 Thinner 50 1107 55350
A/D primer 8.75 1700 14875
Matt 7.5 1220 9150
T-6 Thinner 8 493 3944
Total 334437.75
Oil resistant paint: (7.5 liter *250 Taka) = 1875 Taka
AKZONOBEL PAINT
PAINT NAME CONSUMPTION (liter) COST PER LITER TOTAL COST (tk)
750A 20 390 7800
740B 5 390 1950
Inter Thinner 15 182 2730
52A 10 624 6240
52B 2.5 624 1560
1057A 3 507 1521
1057B 1 507 507
733 Thinner 5 183 915
220 Thinner 10 183 1830
Total 25053
TOTAL COST IN PAINT
PRODUCT SAND
(tk)
CHEMICAL (tk) BERGER (tk) AKZONOBEL (tk) OIL
RESISTANT
PAINT (tk)
TOTAL (tk)
PRICE 26266.26 10625 334437.75 25053 1875 398257.01

15. 14
DIRECT LABOR
Section Total working hour
(effective)
Total Overtime Manpower cost/hr Total Man power
cost (tk)
Transformer Tank 3000 1008.6 30 120258
Radiator 2177.5 1389.75 30 107017.5
Paint 1196 306.125 30 45063.75
Machine Shop 1560 429 30 59670
Core Channel 1375 322.5 30 50925
Total 382934.25
MANUFACTURING OVERHEAD
Electricity cost: 137500 tk
Welding rod at Tank Assembly & CT-PT:
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm 40.85 155 6331.75
4mm 100 155 15500
5mm 225 155 34875
Stainless steel 0.7352 800 588.16
Total 366.5852 155 57294.91
Radiator section:
MATERIAL QUANTITY (kg) UNIT PRICE (tk) TOTAL COST (tk)
Welding Rod 22.32 155 3459.6
Welding wire 99 150 14850
Carbon-di-Oxide 18 134 2412
Total 20721.6
CT-PT
132KV
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm 1.62 800 1294.11
4mm 5.9 155 914.5
TOTAL 2208.61
33KV
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm (CT) 0.97 155 150.35
3.2mm (PT) 1.103 155 171.03
TOTAL 321.38
Gas price
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
Oxygen 12.5 252 3150
LP 0.5 5400 2700
Total 5850

16. 15
Indirect Materials
Butterfly valve: 36 pcs * 2500tk = 90,000tk
Elbow: 1.52kg * 250tk = 380tk
Bush rod: 4pcs * 715tk = 2860tk
U-Bolt: 16set * 60tk = 960tk
Nut-bolts
SIZE PIECE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
20mm 126 25 200 5000
16mm 275 30 200 6000
12mm 450 35 200 7000
8mm 100 5 200 1000
Total 19000
Total Manufacturing Overheads:
Criteria Cost (tk)
Electricity 137500
Welding rod at Tank Assembly 57294.91
Radiator section 20721.6
CT-PT 6625.83
Gas price 5850
Butterfly valve 90,000
Elbow 380
Nut-bolts 19000
U-bolts & Bush rods 3820
Total 341,192.34
55MVA FINAL COSTING
Criteria Tank
Assembly
(tk)
Radiator
Assembly
(tk)
Paint (tk) CT-PT
(tk)
Labor
Cost (tk)
Manufacturing
Overhead (tk)
TOTAL COST
(tk)
Cost 952949.296 958988.88 398257.01 73500 382934.25 341,192.34 3,107,821.776

17. 16
120 MVA
Direct Material Cost: Tank section
HV SIDE TANK WALL
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 HV SIDE PLATE 1672.83 1.00 1672.83 50.00 83641.50 1630.76 42.07 20.00 841.40 82800.10
2 HANDHOLE
FLANGE DIA 480
8.68 3.00 26.03 50.00 1301.50 24.75 1.28 20.00 25.60 1275.90
3 STRENGTHENING 25.44 2.00 50.87 50.00 2543.50 34.45 16.42 20.00 328.32 2215.18
4 LIFTING LUG 22.87 2.00 45.74 50.00 2287.00 43.09 2.65 20.00 52.98 2234.02
5 END PLATE 4.83 2.00 9.66 50.00 483.00 8.68 0.98 20.00 19.60 463.40
6 RIB AT LIFTING 176.86 2.00 353.72 50.00 17686.00 331.84 21.88 20.00 437.64 17248.36
7 RIB 176.86 6.00 1061.16 50.00 53058.00 1034.99 26.17 20.00 523.40 52534.60
8 RIB WITH HOLES 176.87 2.00 353.73 50.00 17686.50 343.11 10.62 20.00 212.32 17474.18
9 RIB AT
HYDRAULIC
JACKING PAD
24.61 2.00 49.22 50.00 2461.00 48.63 0.59 20.00 11.72 2449.28
10 HYDRAULIC
JACKING PAD
33.68 2.00 67.35 50.00 3367.50 67.35 0.00 20.00 0.00 3367.50
11 PIPE FOR
RADIATOR
VALVE
0.73 20.00 14.67 200.00 2934.00 14.67 0.00 20.00 0.00 2934.00
12 FLANGE FOR
RADIATOR
VALVE
4.42 20.00 88.31 50.00 4415.50 88.31 0.00 20.00 0.00 4415.50
13 CABLE HOLDER
CLAMP
0.11 10.00 1.13 50.00 56.50 1.13 0.00 20.00 0.00 56.50
14 EARTHING PAD
M20
0.98 1.00 0.98 250.00 245.00 0.67 0.31 20.00 6.20 238.80
15 EARTHING PAD
M8
0.05 13.00 0.64 250.00 160.00 0.61 0.03 20.00 0.69 159.31
16 FLUX COLLECTOR 72.40 11.00 796.38 240.00 191131.20 796.38 0.00 20.00 0.00 191131.20
17 FLUX COLLECTOR 49.46 6.00 296.73 240.00 71215.20 296.73 0.00 20.00 0.00 71215.20
TOTAL 4889.15 454672.90 4766.16 122.99 2459.88 452213.02

18. 17
LV SIDE TANK WALL
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 LV SIDE PLATE 1672.83 1 1672.83 50 83641.50 1648.54 24.29 20 485.80 83155.70
2 HANDHOLE
FLANGE DIA 480
8.68 5 43.38 50 2169.00 38.70 4.68 20 93.60 2075.40
3 STRENGTHENING 25.44 2 50.87 50 2543.50 34.45 16.42 20 328.32 2215.18
4 LIFTING LUG 22.87 2 45.74 50 2287.00 43.09 2.65 20 52.98 2234.02
5 ENDPLATE 4.83 2 9.66 50 483.00 8.68 0.98 20 19.60 463.40
6 RIB AT LIFTING 176.86 2 353.72 50 17686.00 331.84 21.88 20 437.64 17248.36
7 RIB 176.86 5 884.30 50 44215.00 862.49 21.81 20 436.17 43778.83
8 RIB WITH HOLES 176.86 2 353.72 50 17686.00 343.11 10.61 20 212.12 17473.88
9 RIB AT
HYDRAULIC
JACKING PAD
24.61 2 49.22 50 2461.00 48.63 0.59 20 11.72 2449.28
10 HYDRAULIC
JACKING PAD
33.68 2 67.35 50 3367.50 67.35 0.00 20 0.00 3367.50
11 PIPE FOR
RADIATOR
VALVE
0.73 20 14.67 50 733.50 14.67 0.00 20 0.00 733.50
12 FLANGE FOR
RADIATOR
VALVE
4.42 20 88.31 50 4415.50 88.31 0.00 20 0.00 4415.50
13 CABLE HOLDER
CLAMP
0.11 10 1.13 50 56.50 1.13 0.00 20 0.00 56.50
14 EARTHING PAD
M20
0.98 1 0.98 250 245.00 0.67 0.31 20 6.20 238.80
15 EARTHING PAD
M8
0.05 15 0.74 250 185.00 0.74 0.00 20 0.00 185.00
16 FLUX COLLECTOR 69.94 9 629.49 240 151077.60 629.49 0.00 20 0.00 151077.60
17 FLUX COLLECTOR 69.94 8 559.55 240 134292.00 559.55 0.00 20 0.00 134292.00
18 HOLDER FOR
GAS SAMPLING
DEVICE
0.21 1 0.21 50 10.50 0.21 0.00 20 0.00 10.50
19 PIPE HOLDER 5.95 2 11.89 50 594.50 11.74 0.15 20 2.92 591.58
TOTAL 4837.76 468149.60 4733.41 104.35 2087.07 466062.53

19. 18
RIGHT SIDE TANK WALL
No. Item name Raw unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 RIGHT SIDE
PLATE
597.02 1 597.02 50 29851.00 596.23 0.79 20 15.76 29835.24
2 RIB WITH HOLES 176.86 2 353.72 50 17686.00 343.11 10.61 20 212.12 17473.88
3 SUPPORT FOR
MDU
2.36 2 4.71 50 235.50 4.71 0.00 20 0.05 235.45
4 SUPPORT FOR
MDU
1.12 2 2.24 50 112.00 2.24 0.00 20 0.00 112.00
5 MARSHELLING
BOX FIXING
CLAMP
1.62 4 6.48 50 324.00 6.48 0.00 20 0.00 324.00
6 MARSHELLING
BOX FIXING
STIFFNER
1.41 4 5.65 50 282.50 5.65 0.00 20 0.00 282.50
7 CABLE HOLDER
CLAMP
0.75 4 3.01 50 150.50 3.01 0.00 20 0.00 150.50
8 EARTHING PAD
M8
0.05 2 0.10 250 25.00 0.10 0.00 20 0.00 25.00
9 FLANGE DN50
PN10 gr.
3.46 1 3.46 50 173.00 3.38 0.08 20 1.60 171.40
10 FLANGE DN50
PN10 gr.
3.46 1 3.46 50 173.00 3.38 0.08 20 1.60 171.40
11 OIL DRAINING
PIPE DN50
0.27 1 0.27 50 13.50 0.27 0.00 20 0.00 13.50
12 OIL DRAINING
PIPE ELBOW
DN50
0.77 1 0.77 200 154.00 0.65 0.12 20 2.40 151.60
13 VALVE NAME
PLATE
0.13 2 0.26 50 13.00 0.26 0.00 20 0.00 13.00
TOTAL 981.15 49193.00 969.47 11.68 233.53 48959.47

20. 19
LEFT SIDE TANK WALL
No. Item name Raw
unit
wt
(kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 LEFT SIDE PLATE 597.02 1 597.02 200 119404.00 596.23 0.79 20 15.76 119388.24
2 RIB WITH HOLES 176.86 2 353.72 50 17686.00 343.14 10.58 20 211.52 17474.48
3 DN50 OIL FILLING
PIPE
12.73 1 12.73 200 2546.00 12.53 0.20 20 4.00 2542.00
4 OIL SAMPLING PIPE 7.79 1 7.79 200 1558.00 7.79 0.00 20 0.00 1558.00
5 BOTTOM OIL
SAMPLING PIPE
0.93 1 0.93 200 186.00 0.93 0.00 20 0.00 186.00
6 FLANGE DN50 PN
10 gr.
3.46 1 3.46 50 173.00 3.38 0.08 20 1.60 171.40
7 FLANGE DN15 PN6
gr.
0.55 2 1.09 50 54.50 0.86 0.23 20 4.60 49.90
8 SPACER 0.07 1 0.07 50 3.50 0.07 0.00 20 0.00 3.50
9 SPACER 0.16 1 0.16 50 8.00 0.16 0.00 20 0.00 8.00
10 TRANSPORT OIL
LEVELGAUGE
1.41 1 1.41 50 70.50 1.32 0.09 20 1.78 68.72
11 SUPPORT FOR N2
CHECKING DEVICE
0.40 1 0.40 50 20.00 0.40 0.00 20 0.00 20.00
12 EARTHING PAD
M12
0.06 1 0.06 250 15.00 0.06 0.00 20 0.00 15.00
13 LADDER RUNG 2.18 12 26.16 50 1308.00 26.16 0.00 20 0.00 1308.00
14 NAME PLATE 3.81 1 3.81 50 190.50 3.81 0.00 20 0.00 190.50
15 VALVE POSITION
PLATE
4.60 1 4.60 50 230.00 4.60 0.00 20 0.00 230.00
16 CONNECTION
DIAGRAM PLATE
2.32 1 2.32 50 116.00 2.32 0.00 20 0.00 116.00
17 VALVE NAME
PLATE
0.13 3 0.40 50 20.00 0.40 0.00 20 0.00 20.00
18 FLUX COLLECTOR 69.94 6 419.66 240 100718.40 419.66 0.00 20 0.00 100718.40
TOTAL 1435.79 244307.40 1423.83 11.96 239.26 244068.14

21. 20
BOTTOM PLATE
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 BOTTOM PLATE 2695.38 1 2695.38 50 134769.00 2632.68 62.70 20 1253.98 133515.02
2 SLIDING PLATE 245.17 3 735.51 50 36775.50 727.68 7.83 20 156.60 36618.90
3 HORIZONTAL
CHASSIS RIB
138.24 2 276.48 50 13824.00 273.74 2.74 20 54.86 13769.14
4 VERTICAL
CHASSIS RIB
L=800
18.84 6 113.04 50 5652.00 113.04 0.00 20 0.00 5652.00
5 VERTICAL
CHASSIS RIB
L=795
18.72 12 224.67 50 11233.50 219.73 4.94 20 98.75 11134.75
6 THREADED
ROD
2.27 4 9.06 250 2265.00 9.06 0.00 20 0.00 2265.00
7 SQUARE STEEL 0.55 12 6.65 50 332.50 6.65 0.00 20 0.00 332.50
TOTAL 4060.79 204851.50 3982.58 78.21 1564.19 203287.31
TANK FRAME
No. Item name Raw
unit
wt
(kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 FRAME PLATE
LONG
144.59 2 289.17 50 14458.50 276.05 13.12 20 262.37 14196.13
2 FRAME PLATE
SHORT
50.14 2 100.28 50 5014.00 100.28 0.00 20 0.00 5014.00
3 INNER FRAME
RETAINER
9.53 1 9.53 2000 19060.00 9.53 0.00 20 0.00 19060.00
4 MIDDLE FRAME
RETAINER
9.72 1 9.72 2000 19440.00 9.72 0.00 20 0.00 19440.00
5 OUTER FRAME
RETAINER LONG
3.62 2 7.23 2000 14460.00 7.23 0.00 20 0.00 14460.00
6 OUTER FRAME
RETAINER SHORT
1.39 2 2.78 2000 5560.00 2.78 0.00 20 0.00 5560.00
TOTAL 418.71 77992.50 405.59 13.12 262.37 77730.13

22. 21
ROLLER ASSEMBLY
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 OUTER ROLLER
FLANGE
14.25 2 28.50 50 1425.00 28.50 0.00 20 0.00 1425.00
2 ROLLER WHEEL 48.32 2 96.64 50 4832.00 96.64 0.00 20 0.00 4832.00
3 SHAFT 10.65 2 21.30 50 1065.00 21.30 0.00 20 0.00 1065.00
4 WASHER 0.52 4 2.09 50 104.50 2.09 0.00 20 0.00 104.50
5 SIDE PLATE 35.17 1 35.17 50 1758.50 34.17 1.00 20 20.00 1738.50
6 SIDE PLARE 35.17 1 35.17 50 1758.50 34.17 1.00 20 20.00 1738.50
7 TOP PLATE 29.04 1 29.04 50 1451.94 27.65 1.39 20 27.74 1424.20
8 STIFENEER 0.50 4 1.98 50 99.00 1.70 0.28 20 5.60 93.40
9 PIN 2.15 1 2.15 50 107.50 2.08 0.07 20 1.45 106.05
10 SPLIT PIN 0.12 1 0.12 50 6.00 0.12 0.00 20 0.00 6.00
11 LOCKING
PLATE
0.51 2 1.02 50 51.00 0.97 0.05 20 0.97 50.03
12 SCREW HEX HD 0.03 4 0.10 50 5.00 0.10 0.00 20 0.00 5.00
13 PLAIN WASHER 0.00 4 0.01 50 0.50 0.01 0.00 20 0.00 0.50
14 SPRING
WASHER
0.00 4 0.01 50 0.50 0.01 0.00 20 0.00 0.50
TOTAL 253.30 12664.94 249.51 3.79 75.75 12589.18
CONSERVATOR TANK
N
o.
Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
pric
e
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost
(tk)
Final
cost(tk)
1 CONSERVATOR
SHELL
591.6 1 591.6 50 29580 517.76 73.84 20 1476.8 28103.2
2 CONSERVATOR
OLTC
35.3 1 35.3 50 1765 34.33 0.97 20 19.4 1745.6
3 RIM DIA 1340 23 2 46 50 2300 38.98 7.02 20 140.4 2159.6
4 ENDPLATE 1340 133.4 1 133.4 50 6670 121.44 11.96 20 239.2 6430.8
5 ENDPLATE
WITH FLANGE
MESSKO OLI
133.4 1 133.4 50 6670 124.46 8.94 20 178.8 6491.2
6 ENPLATE DIA
690 WITH
FLANGE
MESSKO OLI
37.7 1 37.7 50 1885 36.04 1.66 20 33.2 1851.8
7 CONNECTION
LEG
23.65 2 47.3 50 2365 39.02 8.28 20 165.6 2199.4
8 CONSERVATOR
LEG 800
30.85 2 61.7 50 3085 60.06 1.64 20 32.8 3052.2

23. 22
10 HANDHOLE
FLANGE WITH
HOLES DIA 380
5 1 5 50 250 4.42 0.58 20 11.6 238.4
11 ATMOSEAL
HANDHOLE
COVER
13.97 1 13.97 50 698.5 13.97 0 20 0 698.5
12 PIPE END 0.9 1 0.9 200 180 0.9 0 20 0 180
13 FLANGE PN10 1.1 1 1.1 50 55 1.06 0.04 20 0.8 54.2
14 PIPE END DN25
L=83
0.3 1 0.3 200 60 0.27 0.03 20 0.6 59.4
15 FLANGE PN10 2.7 1 2.7 50 135 2.59 0.11 20 2.2 132.8
16 SPACER
BOTTOM
0.7 2 1.4 50 70 1.37 0.03 20 0.6 69.4
17 SPACER 0.05 6 0.3 50 15 0.3 0 20 0 15
18 SIDE PLATE OF
FOOT
0.6 2 1.2 50 60 1.14 0.06 20 1.2 58.8
20 SPACER 0.05 2 0.1 50 5 0.1 0 20 0 5
21 ATMOSEAL 0.06 2 0.12 50 6 0.12 0 20 0 6
22 PIPE HOLDER 0.6 1 0.6 50 30 0.55 0.05 20 1 29
23 PIPE HOLDER 1.2 1 1.2 50 60 1.1 0.1 20 2 58
24 BUILD IN OF
AIR VENTPLUG
0.11 2 0.22 50 11 0.22 0 20 0 11
25 LIFTING EYE 0.6 2 1.2 50 60 1.06 0.14 20 2.8 57.2
26 CABLE
HOLDER100
0.1 1 0.1 50 5 0.07 0.03 20 0.6 4.4
27 CABLE HOLDER
400
0.1875 8 1.5 50 75 1.44 0.06 20 1.2 73.8
28 EARTHING
PLATE
0.04666
6667
15 0.7 250 175 0.7 0 20 0 175
TOTAL 1119.0
1
1003.47 115.54 53959.7
TOP PLATE
No. Item name Raw
unit
wt (kg)
Qty. Total
raw
wt
(kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scrap
unit
cost
(tk)
Scrap
cost(tk)
Final
cost(tk)
1 COVER PLATE
ASSEMBLY
3217.66 1 3217.66 50 160883 2863.11 354.55 20 7091.08 153791.92
2 HV TURRET 41.46 3 124.37 50 6218.28 121.17 3.19 20 63.8778 6154.40
3 LV & IV
NEUTRAL
TURRET
28.15 4 112.60 50 5630 106.27 6.33 20 126.7 5503.30
4 SUPPORT OF
BEVEL GEAR
6.55 1 6.55 50 327.6 5.64 0.91 20 18.24 309.36
5 STIFFENER
PIPE
1.01 3 3.02 200 604.8 2.43 0.59 20 11.88 592.92
6 FLANGE FOR 12.01 1 12.01 50 600.5 11.82 0.19 20 3.8 596.70

24. 23
TAP CHANGER
HEAD
7 SPINDLE PIPE 12.51 4 50.04 200 10008 50.04 0.00 20 0 10008.00
8 LIFTING LUG 28.21 4 112.86 50 5642.8 52.00 60.86 20 1217.12 4425.68
9 BUILD IN OF
OVERPR RELIEF
DEVICE
1.85 1 1.85 50 92.25 1.69 0.16 20 3.19 89.06
10 HANDHOLE
FLANGE
6.70 1 6.70 50 334.85 5.99 0.71 20 14.14 320.71
11 FLANGE DN80
PN 10 gr.
3.73 1 3.73 50 186.5 3.43 0.30 20 6 180.50
12 CABLE HOLDER 0.11 16 1.76 50 88 1.76 0.00 20 0 88.00
13 EARTHING
PLATE M8
0.17 3 0.50 250 125 0.50 0.00 20 0 125.00
14 RIB 91.26 3 273.77 50 13688.5 266.25 7.52 20 150.48 13538.02
15 ANIMATING
PLATE
2.23 2 4.47 50 223.35 4.47 0.00 20 0 223.35
16 ANIMATING
PLATE
4.00 1 4.00 50 200 4.00 0.00 20 0 200.00
TOTAL 196146.92
YOKE CLAMP
No. Item name Raw
unit
wt
(kg)
Qty. Total
raw
wt (kg).
Unit
price
(tk)
Raw
cost(tk)
Product
wt (kg)
Scrap
wt
(kg).
Scra
p
unit
cost
(tk)
Scra
p
cost
(tk)
Final
cost(tk)
1 HV TOP & BOTTOM
CLAMP
418.4
05
2 836.81 50 41840.5 830.4 6.41 20 128.
2
41712.3
2 PRESSING PAD END 9.125
625
4 36.5025 50 1825.12
5
36.5025 0 20 0 1825.125
3 PRESSING PAD
MIDDLE
21.35
08
4 85.4032 50 4270.16 79.916 5.487
2
20 109.
744
4160.416
4 CLAW SUPPORT 7.033
6
12 84.4032 50 4220.16 81.448 2.955
2
20 59.1
04
4161.056
5 DESCRIPTION 3.673
8
4 14.6952 50 734.76 12.614 2.081
2
20 41.6
24
693.136
6 BRIDGE SUPPORT 1.256 4 5.024 50 251.2 5.024 0 20 0 251.2
7 STOP PIECE 0.528
8937
5
12 6.34672
5
50 317.336
3
6.14672
5
0.2 20 4 313.3363
8 SUPPORT FIXING
BRACKET
0.528
0333
33
6 3.1682 50 158.41 2.8787 0.289
5
20 5.79 152.62
9 TAPCHANGER
BRACKET
7.85 2 15.7 50 785 15.7 0 20 0 785
10 LIFTING PAD 17.27 4 69.08 50 3454 63.047 6.033 20 120.
66
3333.34
11 RIB 5.667
7
8 45.3416 50 2267.08 45.3416 0 20 0 2267.08
12 HV TOP & BOTTOM
CLAMP
418.4
05
2 836.81 50 41840.5 763.45 73.36 20 1467
.2
40373.3

25. 24
13 FOOT CONNECTION 4.152
65
6 24.9159 50 1245.79
5
24.106 0.809
9
20 16.1
98
1229.597
14 RIB FOR FOOT 1.467
95
6 8.8077 50 440.385 8.8077 0 20 0 440.385
15 FLITCH PLATE 27.59
432
12 331.131
8
50 16556.5
9
331.131
8
0 20 0 16556.59
16 CLAMPING PLATE 3.579
6
12 42.9552 50 2147.76 42.9552 0 20 0 2147.76
17 FEET 115.5
52
3 346.656 50 17332.8 346.656 0 20 0 17332.8
18 CLAW 4.513
75
6 27.0825 50 1354.12
5
27.0825 0 20 0 1354.125
19 TOP BRIDGE 35.59
504
3 106.785
1
50 5339.25
6
106.785
1
0 20 0 5339.256
20 END BRIDGE 123.7
3562
5
2 247.471
3
50 12373.5
6
247.471
3
0 20 0 12373.56
21 SIDE PLATE 11.57
875
4 46.315 50 2315.75 46.315 0 20 0 2315.75
TOTAL 3221.40
5125
3123.77
9125
97.62
6
159117.7
TANK ASSEMBLY
No. DESCRIPTION QTY TOTAL RAW
WEIGHT (kg)
TOTAL PRODUCT
WEIGHT (kg)
TOTAL
SCRAP (kg)
COST (tk)
1 HV SIDE TANK WALL 1.00 4862.14 4766.16 95.98 452213.02
2 LV SIDE TANK WALL 1.00 4838.94 4733.41 105.53 466121.53
3 RIGHT SIDE TANK WALL 1.00 981.15 969.47 11.68 48959.47
4 LEFT SIDE TANK WALL 1.00 1435.79 1423.83 11.96 244068.14
5 TANK BOTTOM PLATE 1.00 4060.78 3982.58 78.20 203287.31
6 TANK FRAME 1.00 418.72 405.59 13.13 77730.13
7 CONSERVATOR
SUPPORT,RIGHT
2.00 91.61 91.61 0.00 4580.50
8 CONSERVATOR SUPPORT,
LEFT
2.00 110.90 106.90 4.00 5465.00
9 RIB 4.00 7.97 7.97 0.00 398.50
10 CONNECTION PLATE 2.00 16.33 16.02 0.31 810.34
11 EARTHING PLATE M8 1.00 0.05 0.05 0.00 12.50
12 ROPE GUIDE 4.00 11.09 11.09 0.00 554.50
13 ROLLER ASSEMBLY 4.00 1519.75 998.04 521.71 12589.18
14 YOKE CLAMP 1.00 3221.405125 3123.779125 97.626 159117.7
15 CONSERVATOR TANK 1.00 1119.01 1003.47 115.54 53959.7
TOTAL 22695.635125 21639.969125 1055.666 1729867.52

26. 25
Direct Material Cost: Current Transformer-Potential Transformer
132KV
Current Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST (tk)
DIA 550mm 66 250 16500
CT Base 40 50 2000
TOTAL 18500
Potential Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST (tk)
MS Sheet 90 50 4500
Oil Chamber 30 50 1500
TOTAL 6000
33KV
Current Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST (tk)
DIA 350mm 31 50 7750
CT Base 13 50 650
TOTAL 8400
Potential Transformer
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST (tk)
MS Sheet 31 50 1550
Oil Chamber 11 50 550
TOTAL 2100
Direct Material Cost: RADIATOR section
ITEM QUANTITY(KG) UNIT PRICE(tk) TOTAL COST (tk)
Sheet Metal 13661 kg 60 tk/kg 819660
Pipe 188 ft Scrap= 12.96kg 200 tk/ft Scrap=20tk/kg 37340.8
Flange 40 piece 360 tk 14400
Attaching rod & holder 109.4 kg 60 tk/kg 6564
Oil nob 40 piece 120tk 4800
Total = 882764.8

27. 26
Direct Material Cost: PAINT section
Item name Total painted surface area (m
2
) Total sand blasted surface area(m
2
)
Tank 540 540
CT-PT tank-base-CC 1015 520
CT/PT Doom cover 200 100
Radiator 1568 0
CC 15 15
Others 195.27 195.27
Total 3533.27 1370.27
Sand (kg)/square meter = 0.854 kg/m2
Sand unit price = 25tk/kg
Sand Cost = 1370.27 * 0.854 * 25 = 29255.26 tk
Chemical Treatment
Chemical Name Consumed(kg) Cost per Kg (Taka) Total cost (Taka)
Gardo Bond C 30 275 8250
Gardo Len 26 M 6.25 380 2375
Total 10625
BERGER PAINT
PAINT NAME CONSUMPTION (gallon) COST PER GALLON TOTAL COST (tk)
Epoxy Primer 32.5 2621 85182.5
Epoxy Enamel 30 2741 82230
C/A for Primer 16.25 2621 42591.25
C/A for Enamel 15 2741 41115
T-7 Thinner 50 1107 55350
A/D primer 8.75 1700 14875
Matt 7.5 1220 9150
T-6 Thinner 8 493 3944
Total 334437.75
Oil resistant paint: (7.5 liter *250 Taka) = 1875 Taka

28. 27
AKZONOBEL PAINT
PAINT NAME CONSUMPTION (liter) COST PER LITER TOTAL COST (tk)
750A 20 390 7800
740B 5 390 1950
Inter Thinner 15 182 2730
52A 10 624 6240
52B 2.5 624 1560
1057A 3 507 1521
1057B 1 507 507
733 Thinner 5 183 915
220 Thinner 10 183 1830
Total 25053
Total Cost in Paint Section:
PRODUCT SAND (tk) CHEMICAL(tk) BERGER(tk) AKZONOBEL(tk) OIL
RESISTANT
PAINT(tk)
TOTAL(tk)
PRICE 29255.26 10625 334437.75 25053 1875 401246.01
DIRECT LABOR
Section Total working hour
(effective)
Total Overtime (hr) Manpower cost/hr Total Man power
cost (tk)
Transformer Tank 3000 1008.6 30 120258
Radiator 2177.5 1389.75 30 107017.5
Paint 1196 306.125 30 45063.75
Machine Shop 1560 429 30 59670
Core Channel 1375 322.5 30 50925
Total 382934.25

29. 28
MANUFACTURING OVERHEAD
Electricity cost: 137500 tk
Welding rod at Tank Assembly & CT-PT:
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm 55.85 155 8656.75
4mm 135 155 20925
5mm 305 155 47275
Stainless steel 1.03 800 823.529
Total 496.88 155 77680.279
Radiator section
MATERIAL QUANTITY (kg) UNIT PRICE (tk) TOTAL COST (tk)
Welding Rod 22 155 3410
Welding wire 92 150 13800
Carbon-di-Oxide 20 114 2280
Total 19490
CT-PT
132KV
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm 1.62 800 1294.11
4mm 5.9 155 914.5
TOTAL 2208.61
33KV
SIZE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
3.2mm (CT) 0.97 155 150.35
3.2mm (PT) 1.103 155 171.03
TOTAL 321.38
Gas price
Gas Quantity (Cylinders) Unit price/Cylinder Total price
Oxygen 12.5 252 3150
LP 0.5 5400 2700
Total 5850
Indirect Materials
Butterfly valve: 36 pcs * 2500tk = 90,000tk
Elbow: 1.52kg * 250tk = 380tk
Bush rod: 4pcs * 1280tk = 5120tk
U-Bolt: 24set * 60tk = 1440tk
Radiator Fan: 10pcs * 67500tk = 675000tk

30. 29
Nut-bolts
SIZE PIECE WEIGHT (kg) UNIT PRICE (tk) TOTAL COST (tk)
20mm 152 30 200 6000
16mm 275 30 200 6000
12mm 450 35 200 7000
8mm 100 5 200 1000
Total 20000
Total Manufacturing Overheads:
Criteria Cost (tk)
Electricity 137500
Welding rod at Tank Assembly 77680.279
Radiator section 19490
CT-PT 6625.83
Gas price 5850
Butterfly valve 90,000
Elbow 380
Nut-bolts 20000
U-bolts & Bush rods 6560
Radiator Fan 675000
Total 1,039,086.109
120MVA FINAL COSTING
Criteria Tank
Assembly
(tk)
Radiator
Assembly
(tk)
Paint (tk) CT-PT
(tk)
Labor
Cost (tk)
Manufacturing
Overhead (tk)
TOTAL COST
(tk)
Cost 1729867.52 882764.8 401246.01 73500 382934.25 1,039,086.109 4,509,398.689

31. 30
PRICE LIST OF POWER TRANSFORMERS
N
O
POWE
R
RATIN
G
TANK ASSEMBLY RADIATOR
ASSEMBLY
CT-PT PAINT LABOR
COST
(TK)
MANUFACTURING OVERHEAD TOTAL
COST
(TK)PRODUC
T WT.
(KG)
FINAL COST
(TK)
N0
OF
LAY
ER
FINAL
COST
(TK)
COST
(TK)
PAINTED
AREA
(M2
)
FINAL COST
(TK)
COST
RELATIVE
TO WEIGHT
(TK)
RAD
IAT
OR
FAN
FINAL COST
(TK)
1 4 MVA 1780 138359.4 108 172800 31500 338.20 39907.60 382934.25 35066 0 35066 800567.3
2 5 MVA 2300 178779 96 153600 31500 437.00 51566.00 382934.25 45310 4 129310 927689.3
3 12.5 -
15
MVA
6330 492030.9 10 16000 31500 1202.70 141918.60 382934.25 124701 0 124701 1189084.8
4 8 MVA 4615 358723.9 300 480000 31500 876.85 103468.30 382934.25 90915.5 0 90915.5 1447542
5 20-25
MVA
10150 788959.5 448 716800 31500 1928.50 227563.00 382934.25 199955 8 499955 2647711.8
6 55
MVA
14865.8 952949.3 594 958988 73500 3236.47 398257.01 382934.25 341192.34 0 341192.34 3107821.8
7 40-50
MVA
12590 978620.7 480 768000 73500 2392.10 282267.80 382934.25 248023 8 668023. 3153345.8
8 50-75
MVA
14865.8 1155517.9 528 844800 73500 2824.50 333291.01 382934.25 292856.06 8 772856.06 3562899.2
9 120
MVA
22253 1729867.5 560 882764 73500 3533.27 401246.01 382934.25 364086.11 10 1039086.11 4509398.7
CONCLUSION:
Our primary assignment was to make a list of price for all the transformers produced in this factory. Finally we
have managed to make a price list of some power transformers.
We have tried our best to get perfect figures for every calculation. But due to lack of time and other difficulties
there are some errors in the final costs. As we studied only two transformer designs (55MVA & 120MVA)
thoroughly we managed to get approximately correct cost for these two transformer production. Using data found
in these two products we projected the costing of other Power transformers produced here.
During these four weeks we have learned many things which will help us in future in any kind of Factory we work
in. The in depth study of Production process helped us understand all the aspects of a factory and hopefully this
knowledge will help us in our professional life.