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Contents17.7 Marina electrical installation59017.8 Construction and demolition sites59217.9 High-voltage electrical installations594SummaryChapter 18595Workshop fabrication59718.1 Workshop safety practices59818.2 Tools used in electrical work60018.3 Materials used for custom components60418.4 Job planning60618.5 Cutting and shaping62118.6 Drills and drilling62718.7 Thread cutting and tapping63118.8 Joining components63518.9 Dismantling and assembling 9 fm i-xviii.inddxi 09/04/18 12:05 PM

About the authorsKeith PethebridgeKeith Pethebridge, a passionate teacher and mentor, sadly passed away in March 2010. However, his insight andcommitment, going as far back as the 1970s, to creating a text devoted to electrical wiring lives on. Now in itseighth edition, Electrical Wiring Practice can be regarded as Keith’s legacy to the electrical industry. Thanks, Keith.Ian NeesonIan Neeson is a vocational education and training consultant specialising in electrotechnology.He was involved in the development of the National Competency Standards forElectrotechnology and continues to provide assistance to the National ElectroComms andEnergy Utilities Skills Council (EE-Oz Training Standards) in its program of continuousimprovement.Ian also represents the National Skills Council on the Wiring Rules Committee (EL-001)and Hazardous Areas Competency Standards Committee (P-12). He is a member of an IECExWorking Group for Personnel Competencies. For the past few years, Ian has also been a member of the judgingteam for the National Electrical and Communications Association (NECA) NSW Excellence Awards.Paul LowePaul Lowe has been involved in the electrotechnology field for over 35 years. During the past14 years Paul has worked for TAFE NSW as a teacher, head teacher and, more recently, asIndustry Liaison Manager responsible for electrotechnology across NSW.He has been an active participant in the development of training package qualificationsand units for the last six years and is a member of several technical advisory committees,representing NSW in the National Technical Advisory Group. He is currently part ofthe Commonwealth Industry Skills Committee as a technical expert, representing theElectrotechnology Training Package.xiipet21069 fm i-xviii.inddxii 09/04/18 12:05 PM

AcknowledgmentsThe production of a book covering such a wide range of topics would not be possible but for the contributions madeby members of the electrotechnology industry in Australia and New Zealand. Our thanks go to these groups andorganisations, who are listed below and cited throughout the text: ABB RoboticsBoutique PowerClipsal, Schneider ElectricEDMIEmona InstrumentsFuji SMBE HarwalHeyday GroupNational Electrical and CommunicationsAssociation (NECA) NATSPEC Olex CablesPhilipsPowerGen AustraliaRedflowSAI Global LtdSelectronicStand Alone Power SystemsStandards AustraliaTeslaPermission to reproduce the cover of AS/NZS 3000:2018 given by SAI Global Ltd. This Standard can be purchasedonline at www.saiglobal.com.The development of this edition would not have been possible without the help and encouragement of ourcolleagues in vocational education and training and in industry. Particular thanks go to Antony Neeson for hisartistic prowess.We would also like to thank the publishing team at McGraw-Hill for their hard work throughout the productionof this book: Norma Tomaras, Apeksha Rao and Daisy Patiag.Keith’s legacy lives on.Ian Neeson and Paul Lowexiiipet21069 fm i-xviii.inddxiii 09/05/18 11:14 AM

Work and electrical safety Chapter 2INFORMATION, TRAINING AND INSTRUCTIONYour employer is required to provide a healthy and safe workplace. The very nature of maintaining a healthy andsafe workplace means that training must be ongoing. Familiarity and complacency can pose the highest risk. Itdiagrams,schedulesandinformationdocumentsin electricalworkChapteris commonly the roleDrawings,of an immediatesupervisorto provide clearandusedinstructionon the workathand and be satisfied you are trained to do the work in the role you are given. The emphasis being on safetyengaging with this through pre-start and tool-box talks. Once started on a worksite some of the most importantP3P3P3things are:222possible hazards and unsafe situations particularly in unfamiliar work environments and the safe workmethods to be appliedreceive clear P3VP2VP4understand and accept the safe work methods to be usedM work method statementMPPP to be used asMprescribed in the safe(SWMS) or jobM safety analysis (JSA)L3participatein any safety discussionL1L2Text at a glanceElectrical energyLearning outcomest ppMLCSUPERVISORSAdditional WHS training is provided for supervisors as they needa greater understanding of workplace hazards and control measures.This is particularly important for supervising apprentices.12ApparatusCableInformation boxesLPDB2P3Cables, connections and terminations Chapter 41 3 C E 70 mm2 R-HF-110 sheathed cableVacuum pump powerSupport/protectionCable ladderMLCMotor Load CentreLPDB Light and power distributionTable 4.1mustComparison of copper and aluminiumspecificconductorselectrical work, as summarised in Figuretraineesboard 2.2a, which are a1 8 C E 1.5 mm2 R-HF-110tosheathedcableand control undertake WHS competenciesVPVacuum pumpprerequisiteto all other competenciesrequired in order to achieve theCablestatusof ‘electrician’.1 3 C E 10 mm2 R-HF-110 sheathed cableladderCooling water pumpsFeaturesCopper conductorAluminiumconductorCWP Cooling water pumpAs shown in Figure 2.2a, WHS induction2 continues with the enterprise you work for and, over time, as electricalCable ladder2 4 C 1.5 mm R-HF-110 sheathed cableVacuum pump localLLight aveitsowninduction,whichwillcoverat a minimum ancontrols materialConductorMade with a high degree of purity exceeding 99.5%PPower circuitorientationto the workplace layoutand facilities, and any specific hazards.HFT conduit50W LED low bay pendant2.5 mm insulated cables and earthLight and powerHighertensile strengththan aluminiumOne-thirdtheonweightof copperFurther to this, workinformationand trainingrelated to safety areprovidedan ongoingbasis, and you areobligated to participate in this, as summarised in Figure 2.2b.These box features highlight dangers, hazards andinformation that students should be aware of in the field.Figure6.4f Architectural/engineer’s electrical plan of a plant roomConductivityApproximately 60% that of copperCurrent-carryingcapacityAbout 80% that of copper for the same sizeconductor6.5Working with specifications, schedules and drawingsCAUTIONSusceptibility tocorrosionResistant to corrosion in unpollutedenvironments, but affected by ammoniaA surface oxide forms on aluminium that has avery high resistanceElectrical workersandin sulfurserviceor maintenance roles will often find themselves in unfamiliar workingfumesAt some point in your career, you may choose to move into job supervision, leading to project management orenvironments. Each time electrical workers encounter an unfamiliar workplace, they should requestestimatingpreparation,where youwill work more closelywithspecifications.However,the mostJoiningandand movedandan orientationon Canthe behealthandsafetyorhazardspresent, and theproceduresfor becontrollingthe risk ofimmediateforanya persontraining is extractinginformationas a startto learningterminatinguse of specificationsjoined withoutspecial inprecautionspreventedfrom formingbetweenjointed to planillness or injury in the unfamiliar environment.surfaces with a neutralising paste; the high– explain the principles for producing electricity– explain the reasons for the adoption of alternating current (a.c.) for the main electricity powerLEARNINGOUTCOMESsupply system– describe the advantage and applications of modern direct current (d.c.) transmissionAfteryou thecompletethischapterand thelearningexperiences,– identifyconductorsandtheir purposein a relevantthree-phasedistributionsystemyouwill behowableto:– illustrateelectricityis transmitted and distributedbasic legalrequirementshealthand safety in the workplace—– describeillustrate the differentarrangementsofcoveringdistributionto consumers—steps in managinghealthand safetywithinrisk inantheworkplace– explaindescribethethebasicarrangementsfor aininginstruction requirementsmust be undertaken– outlinediscussthethesafetyprocessesfor andthe connectionof electricity tothata consumer’sinstallationbeforeand thestartingwork activityneed foranycompliancewith safety standards.— identify common potential workplace hazards and typical measures for accident prevention— follow safe work methods for personal safety in the workplace— identify the types of personal protective equipment needed for a particular task— work safely with hand and electrical tools— describe the method for ensuring that an electrical installation is safe to usethe purpose ofelectricitythe earthing system1.1— explainProducing— safely and correctly connect flexible cords and extension leads— outline the reasons for special precautions for installations in damp areasRegulations and Standards Chapter 3— describethe risksandproducedcontrol measureswith high-voltage,low-voltage,extra-lowThe bulkof electricalenergytoday is associatedobtained froma rotating turbineattachedto an electricalChapter introductionEvery chapter commences with an introduction tovoltageandhigh currentsgeneratorthat useselectromagneticinductionto produceenergy(Figure1.1a). Energyused sallows formuchmoreinnovationin installationdesign,at the— demonstratesafeproceduresrescueof a victimof low-voltageelectricshockis extractedfrom steam,flowingwater, forhotthegasesand wind.In Australia,as theyin manyothercountries,the primesametime requiringa completeunderstandingof electricalprinciplesand howapply,particularlyin relationto—demonstratethe applicationof CPR isforcoal.an ewableconceptstoandbein the text.providing protectionsafetycoveredin electrical installations.energy sources driven by the need to reduce greenhouse gas emissions from burning fossil fuels. In a numberThis 2000 edition was criticised for the absence of information that had been in previous editions that helped inof other countries,nuclearenergytheis 2007the primesource.Althoughare similarin manyapplyingthe Standard.As a result,editionand nowthe eguidanceonrespectsto otherthermalpower stations,are identifiedseparatelybecause of the additional equipmentways to complywiththe fundamentalsafety theyperformanceprinciplesof the Standard.requiredto controlthe process,thein associatedrisk isofonea nuclearaccidentand theproblemsof nuclearwasteLearninghow to achievesafetythe workplaceof the mostimportantaspectsof yourvocationalcontainment.training and education, and you will continue to put this knowledge into practice throughout your workingAdditionally,therearemultiplemany smallgenerators for electricity supply in areas remote fromlife.Electricianshaverolesdieselwhen engine-drivenit comes to safety.main powerprevalentas standbysupply orks.they mustThesecarry areoutbecomingtheir workmoresafelyand observeall measuresto protectthemselvesthatandelectricityproducedfor themain powernetworkis alternatingcurrent,which hashazards,some distinctadvantagesfellow workersagainstworkplacehazards.In additionto commonworkplacethey mustalsooverdirectdealwithcurrent.the dangers of working with electricity. This requires an understanding of the use of work safetypracticesand KNOW?how safety is managed in the workplace, including a willingness to cooperate with otherDID YOU1workers to recognise and deal with health and safety risks.Secondly,electricianshaveliabilityto ensurethat the electrical systems and equipment they installThe best way to learn howtoausethe WiringRulesand maintain are safe and remain safe for all those who use them. This requires a thorough knowledge ofStart with the 1‘Content’, as illustrated in the following Figures 3.3a to 3.3e. You will see that the09/04/18Wiringpet21069 ch01 001-018.indd11:20 AMelectrical principles,the Wiring Rules and regulations, and the skills to apply this knowledge.Rules follows a logical plan. The Rules commence at the supply end of the installation through toIn addition to this, if an accident does occur, those able to give assistance should know how to rescuerequirements for the selection and installation of wiring, equipment and earthing; these are followed bya victim safely and how to apply emergency treatment.requirements for special types of installations and then verification by inspection and testing. It finisheswith Appendices for information and guidance in applying the requirements of the Standard. Althoughtackling the Wiring Rules may seem difficult at first, by viewing the eight sections as a series of eight 19separate books (with the Appendices as the ‘help’ file), the task of using it will become much easier.The Wiring Rules also includes an index which should only be used once you have become adept atreferencing information from the content.pet21069 ch02 019-048.indd 1908/07/18 12:08 PMLearning the Wiring Rules AS/NZS 3000:2018ExercisesThroughoutthe bookarewrittena number of exercises for3.3.1 How the WiringRules areThe Wiring Rulesto(commonlyknown as knowledge.‘the Rules’) are written in the form of clauses designated by a pointstudentstest theiran installation. You will probably start with a small component of an installation, say, the installation of a finalcoefficient of expansion must be consideredsubcircuit. Initially this will require the compiling of a materials list.when joining and terminatingIn planning an installation and compiling a materials list, the correct interpretation of the plans, specificationsand/orschedules is of fundamentalimportance.mustwiringbe familiarAwiththelighterstandardusedandin plans;ApplicationThe most commonlyused inYougeneralmuchmetalsymbolsthan copperso a anyThe continuingneedto worksafely meansthat youare planobligatedto keepupdatingyour cablesWHS knowledge.popularconductorfor aerialnon-standardisedonesshouldbe containedin a legendon theitself.Updates are easily obtained through the relevant authority websites, given at the end of this chapter.Usedsolid conductorsin large sizesConductorsize you haveFor ageneralwiring, sizea single-wireRemember,responsibilityto ofworksafely bycopperfollowingtheforcorrectsafety proceduresat allastimes.softer than copper and bends more easilyconductor is not more than 2.5 mm2 (1/1.78).If you believeyouPracticeareLargerbeingsolidexposedto a hazardElectricalWiringconductorsused in withoutmineral- sufficient controls in place, or you have any doubtsATTENTIONabout health and safetyin yourmetal-sheathedworkplace, youare entitledto forraise the issue with your supervisor or employeeinsulated(MIMS)cables andbusbars, some earthing conductors, trolley andrepresentative.Don’t rely on memory—write it down. Even on small jobs, several weeks can pass between roughing in thecollector wireswiring andfitting out. If the jobis a renovation,the cableroutesyou wouldmeasuresnormally use in a new structure2.3Workplacehazardsandriskcontrolmay not be accessible, often resulting in convoluted cable runs. A record in a job notebook and on a planof what you intend to do and what you have done can save a lot of time and prevent costly mistakes.23many strands of thin wire. The conductor of a cable core can be single-strand or multistrand, while the cable itselfA commitment to work safety starts with the enterprise undertaking the work, be this a small or large company orcanbe single-core 23or multicore.pet21069 ch02 019-048.indd08/07/18 12:08 PMeven a sole trader. The commitment is usually reflected in a written policy about how the enterprise will manageBoth copper and aluminium cables use stranded-type conductors, although aluminium conductors are more177WHS and related aspects like risk.commonly solid-core, and are cheaper and easier to join but less flexible than stranded cables. Some large copperMany industry bodies provide advice on managing WHS including templates for risk management policycables for special uses have their flexibility increased by bunch stranding or rope lay.and safe work method statements (SWMS). The National Electrical and Communications Association (NECA)has developed a number of these documents that are applicable to the electrotechnology industries. Although atpet21069 ch06 151-186.indd 17708/09/18 01:35 PMthis stageof yourapprenticetraining you will have limited levels of knowledge and skills in electrical work, it isAS/NZS3008.1SERIESimperative that you understand the hazards and risks, and follow all safety instructions and requirements.Table2.1 outlinessome of the moreofimmediatemanagementpoliciesand ctioncables Part1: Cables foralternatingvoltagesup to and by NECANSWincludingwith regards0.6/1toksafety.VThis importantStandardrulesgives all the information about cables and, together with the Wiring Rules, is2.3.1Lifesavingused by electricians when planning electrical installationCables,work. It is publishedandas Part 1.1 for Australian4The conditionslifesaving rulesare a1.2setforofNewrulesZealandthat are conditions.intended to be strictly connectionsapplied across allterminationsworksites andChapterthat relateand Partspecifically to high-risk activities.as eandneutralfunctionsofconductors;however,These rules are an industry benchmark and are reviewed by NECA NSW, together with other organisations.aCables easedmayflexibility1.4.24)aretermed flexiblecables,conductorwitharegreen/yellow,or yellowbe(Clauseusedundercircumstancesas anactiveandorThey are designedto protect employeesand contractorsfromnotseriousinjuryor anydeath,and have beenadoptedbytheir flexibilityis achieved with a conductor of many small-diameter strands. For example, a

6.1 Series and parallel circuits in wiring 152 6.2 Electrical circuits and wiring diagrams 153 6.3 Circuits in general wiring 159 6.4 Undertaking electrical work 171 6.5 Working with specifications, schedules and drawings 177 6.6 Use of software and mobile devices in electrical work 180 Summary 182 Chapter 7 Wiring and cabling systems 187