ENGINEERING

WORKSHOP
PRACTICE
BMT 04205
FACILITATOR: ENG FWEZI. P. L
 INTRODUCTION
What is an engineering workshop?
Engineering workshop is the laboratory which provides both the area
and tools (or machinery) that may be required for the manufacture or
repair of manufactured goods.
What is the use of engineering workshop?
Workshop practice is the backbone of the real industrial environment
which helps to develop and enhance relevant technical hand skills
required by the technician working in the various engineering industries
and workshops.
 WORKSHOP SAFETY RULES AND
REGULATION (BENCH WORKERS)
Safety means protection from, or not being exposed to the risk of
harm or injury.
 Carry out all your activities with care and caution.
 All accidents whether minor or fatal must be reported.
 You must always wear goggles and nose mask during welding,
drilling and metal or wood cutting.
 Return all tools and accessories to their proper storage areas after
use.
 WORKSHOP SAFETY RULES AND
REGULATION (MACHINES)
 Safety goggles should be worn when performing machining operations
to protect the eyes from flying particles.
 Loose-clothing should not be worn in order to prevent being caught by
revolving parts of machines.
 Before operating any machines, time should be taken to make sure
that the machines are completely in order.
 No attempt should be made to remove chips from the machine with
hands.
 No attempt should be made to stop machines with hands even when
the power has been switched off.
 Avoid touching any moving parts of the machine and do not lean on it.
 Workshop/machines must be cleaned each day after work.
 WORKSHOP SAFETY DEVICES
To maintain safety in the workshop, practical safety devices should be
provided and used to protect delicate parts of the body. These include:
 Hand gloves: To protect the palms and fingers
 The shield or safety goggles: To protect the eyes.
 Boots / Hard sole shoes: To protect the legs, the feet and the toes.
 The Helmet: To protect the head.
 Overall: To protect the chest and body generally.
 Nose mask: To protect the nose from inhaling dust.
 Fire extinguisher and sand buckets: These are to be used to stop fire
from destroying lives and property.
 ELECTRICAL WIRING
What is Electrical Wiring?
Electrical Wiring is a process of connecting cables and wires to the
related devices such as fuse, switches, sockets, lights, fans etc to the
main distribution board.

Methods of Electrical Wiring Systems

Wiring (a process of connecting various accessories for distribution of
electrical energy from supplier’s meter board to home appliances such
as lamps, fans and other domestic appliances is known as
Electrical Wiring) can be done using two methods which are
 Joint box system or Tee system
 Loop – in system
Joint Box or Tee or Jointing System
In joint box system the connections to the lamps are made through
joints made in joint boxes by means of suitable connectors or joint
cutouts. In this method though there is a saving in the quantity of wire
or cable required but the same is offset by the extra cost of joint boxes.
The other disadvantage of T-connections is that the number of T-
connections made in a wiring system results in weakness if not
properly made. Now-a-days the use of this system is limited to
temporary installations only, as its cost is low.
Loop- in- system
This system is universally employed for connections of various lamps or
other appliances in parallel. In this system when a connection is
required at a light or switch, the feed conductor is looped-in by bringing
it direct to the terminal and then carrying it forward again to the next
point to be fed, as shown in figure below. The switch and light feeds are
carried round the circuit in a series of loops from one point to another
until the last point on the circuit is reached.
The phase or line conductors are looped either in switch board or box
and neutral conductors are looped either in switch board or from light
or fan. Line or phase should never be looped from light or fan.
Advantages of Loop-In Method of Wiring
 It doesn’t require joint boxes and so money is saved
 In loop – in systems, no joint is concealed beneath floors or in roof
spaces.
 Fault location is made easy as the points are made only at outlets so
that they are accessible.
Disadvantages of Loop-In Method of Wiring
 Length of wire or cables required is more and voltage drop and copper
losses are therefore more
 Looping – in switches and lamp holders is usually difficult.
Different Types of Electrical Wiring Systems
The types of internal wiring usually used are;
 Cleat wiring
 Casing and capping wiring
 Batten wiring
 Lead sheathed or metal sheathed wiring
 Conduit wiring

There are additional types of conduit wiring according to Pipes

installation
(Where steel and PVC pipes are used for wiring connection and
installation).
 Surface or open Conduit type
 Recessed or concealed or underground type Conduit.
Cleat Wiring
This system of wiring comprise of ordinary VIR or PVC insulated wires
(occasionally, sheathed and weather proof cable) braided and
compounded held on walls or ceilings by means of porcelain cleats,
Plastic or wood.

Cleat wiring system is a temporary wiring system therefore it is not

suitable for domestic premises. The use of cleat wiring system is over
nowadays.
Advantages of Cleat Wiring:
 It is simple and cheap wiring system
 Most suitable for temporary use i.e. under construction building or
army camping
 As the cables and wires of cleat wiring system is in open air,
Therefore fault in cables can be seen and repair easily.
 Cleat wiring system installation is easy and simple.
 Customization can be easily done in this wiring system e.g.
alteration and addition.
 Inspection is easy and simple.
Disadvantages of Cleat Wiring:
 Appearance is not so good.
 Cleat wiring can’t be use for permanent use because, Sag may be
occur after sometime of the usage.
 In this wiring system, the cables and wiring is in open air, therefore, oil,
Steam, humidity, smoke, rain, chemical and acidic effect may damage
the cables and wires.
 It is not lasting wire system because of the weather effect , risk of fire
and wear & tear.
 It can be only used on 230/415 Volts on low temperature.
 There is always a risk of fire and electric shock.
 It can’t be used in important and sensitive location and places.
 It is not lasting, reliable and sustainable wiring system
Casing and Capping wiring
One of the oldest and most commonly seen wiring in use today is
casing capping wiring.
PVC-insulated wires are encased in plastic or wood casings and
protected with a cap in this approach to electrical wiring. The casing
capping wiring is generally recommended for low-voltage wiring in
homes, offices, and devices, as well as for wire distribution and
protection

PVC casing and capping is a fantastic product that has many uses in
wiring installations. They offer insulation and electrical safety and
support the distribution load of the wires in accordance with their
capacity. PVC has the highest level of chemical resistance available,
making it the most durable material on the market. It also aids in
shielding the cables and wires from damage.
Advantages of Casing Capping Wiring:
 It is cheap wiring system as compared to sheathed and conduit
wiring systems.
 It is strong and long-lasting wiring system.
 Customization (modification) can be easily done in this wiring
system.
 If Phase and Neutral wire is installed in separate slots, then
repairing is easy.
 Stay for long time in the field due to strong insulation of capping
and casing..
 It stays safe from oil, Steam, smoke and rain.
 No risk of electric shock due to covered wires and cables in casing
& capping.
Disadvantages Casing Capping Wiring:
 There is a high risk of fire in casing & capping wiring system.
 Not suitable in the acidic, alkalies and humidity conditions
 Costly repairing and need more material.
 Material can’t be found easily in the contemporary.
 White ants may damage the casing & capping of wood.
Batten Wiring
A type of wiring which is done on concrete or ripe walls above a long and
smooth wooden batten by means of passing wires through the buckle
clips installed at an equal distance via brass kneels is known as batten
wiring.
In other words, in this form of the wiring system, wires are fitted on a
smooth wooden batten with the help of clips. This wooden batten is fixed
tightly on rawl plugs mounted above the wall through screws.
Advantages of Batten Wiring
 This method of wiring is simple and easy
 As compared to other wiring systems, this method is cheap
 If wiring is done in an expert manner, it looks very decent and
seemly
 It is easy to find out fault or defect due to exposed wires
 This type of wiring system is enduring and durable
 Addition or alteration in this type of wiring system is relatively easy
 Repairing and looking after this type of wiring system is easy
 It has a long life
 This type of wiring can be installed easily and quite quickly
 There is a less possibility of current leakage in this type of wiring
Disadvantages of Batten Wiring
 This type of wiring cannot be used in places with high moisture
chemical effects
 This wiring system is prone to catching fire
 It is not protected against weather effects and external concussions.
 As wires are visible, therefore they are affected by sunlight, dust,
steam, smoke, etc.
 It is not possible to use quite a heavy wiring in this type of wiring
system.
 It can be used up to 250 volts only
 A large quantity of cable is used under this system.
Lead Sheathed Wiring
The type of wiring employs conductors that are insulated with VIR and
covered with an outer sheath of lead aluminum alloy containing about
95% of lead. The metal sheath given protection to cables from
mechanical damage, moisture and atmospheric corrosion.

The whole lead covering is made electrically continuous and is

connected to earth at the point of entry to protect against electrolytic
action due to leaking current and to provide safety in case the sheath
becomes alive. The cables are run on wooden batten or sometimes
without batten. The wire is supported by means of the clips.
Advantages
 It provides protection against mechanical injuries.
 It is easy to fix and looks nice as it can be run in building without
damaging decoration and can be painted to suit color scheme of the
surroundings.
 Its life is long if proper earth continuity is maintained throughout.
 It can be used in damp situations provided protection against
moisture effect on the ends of the cable is given.
 It can be used in situations exposed to rain and sun provided no joint
is exposed.
Disadvantages
 It is costlier than other type of wiring
 It is not suitable for places where chemical corrosion may occur.
 In case of damage to insulation the metal sheath becomes alive and
gives shock, so as to provide safety against electrical shock it is
necessary that the sheath is properly earthed and an earth wire is
run side by side with it and all pieces are properly bounded or joined
together so that not a single cover is left unearthed.
 Skilled labor and proper supervision is required.
Fields of Application
This wiring system is suitable for low voltage (up to 250 volts)
installations. It may be used in places exposed to sun and rain
provided no joint is exposed. It may also be used in damp places with
a suitable protective covering. It should not be used in places where
chemical corrosion may occur.. This type of wiring is not very common
in use these days except for some small installations and distribution
boards etc.
Conduit Wiring
There are two additional types of conduit wiring according to pipe
installation
 Surface Conduit Wiring
 Concealed Conduit Wiring
Surface Conduit Wiring
If conduits installed on roof or wall, It is known as surface conduit
wiring. in this wiring method, they make holes on the surface of wall
on equal distances and conduit is installed then with the help of rawal
plugs(fisher).
Concealed Conduit wiring
If the conduits is hidden inside the wall slots with the help of
plastering, it is called concealed conduit wiring. In other words, the
electrical wiring system inside wall, roof or floor with the help of
plastic or metallic piping is called concealed conduit wiring.
obliviously, It is the most popular, beautiful, stronger and common
In conduit wiring, steel tubes known as conduits are installed on the
surface of walls by means of pipe hooks (surface conduit wiring) or buried
in walls under plaster.
In Conduit wiring system, The conduits should be electrically continuous
and connected to earth at some suitable points in case of steel conduit.
Conduit wiring is a professional way of wiring a building. Mostly PVC
conduits are used in domestic wiring.

The conduit protects the cables from being damaged by rodents (when
rodents bites the cables it will cause short circuit) that is why circuit
breakers are in place though but hey! Prevention is better than cure. Lead
conduits are used in factories or when the building is prone to fire
accident. Trunking is more of like surface conduit wiring. It’s gaining
popularity too. It is done by screwing a PVC trunking pipe to a wall then
passing the cables through the pipe. The cables in conduit should not be
too tight.
Types of Conduit
Following conduits are used in the conduit wiring systems (both
concealed and surface conduit wiring) which are shown in the above
image.
 Metallic Conduit
 Non-metallic conduit
Metallic Conduit:
Metallic conduits are made of steel which are very strong but costly as
well.
There are two types of metallic conduits.
 Class A Conduit: Low gauge conduit (Thin layer steel sheet conduit)
 Class B Conduit: High gauge conduit (Thick sheet of steel conduit)
Non-metallic Conduit:
A solid PVC conduit is used as non-metallic conduit now a days, which is
flexible and easy to bend.
Size of Conduit:
The common conduit pipes are available in different sizes genially, 13,
16.2, 18.75, 20, 25, 37, 50, and 63 mm (diameter) or 1/2, 5/8, 3/4, 1,
Advantage of Conduit Wiring Systems
 It is the safest wiring system (Concealed conduit wring)
 Appearance is very beautiful (in case of concealed conduit wiring)
 No risk of mechanical wear & tear and fire in case of metallic pipes.
 Customization can be easily done according to the future needs.
 Repairing and maintenance is easy.
 There is no risk of damage the cables insulation.
 It is safe from corrosion (in case of PVC conduit) and risk of fire.
 It can be used even in humidity , chemical effect and smoky areas.
 No risk of electric shock (In case of proper earthing and grounding of
metallic pipes).
 It is reliable and popular wiring system.
 Sustainable and long-lasting wiring system.
Disadvantages of Conduit Wiring Systems
 It is expensive wiring system (Due to PVC and Metallic pipes, Additional
earthing for metallic pipes Tee(s) and elbows etc.
 Very hard to find the defects in the wiring.
 Installation is not easy and simple.
 Risk of electric shock (In case of metallic pipes without proper earthing &
grounding system)
 Very complicated to manage additional connection in the future.