TECHNICAL ALERT

CONSULTING SERVICES
DEPARTMENT
SUBJECT: Unsafe 480V Controlgear ALERT NO: DATE:
Padlocking Mechanism 36 May 9, 1999

SUMMARY
The individual switching assemblies1 within the ABB Center 5000 model of Controlgear2 can
not be safely padlocked in the OFF position. If a padlock is attached to the breaker operating
handle when the handle is in the OFF position, the compartment door can be opened. Since the
handle is an integral part of the door, with the door open the padlock is no longer locking-out the
circuit breaker.
1 “switching assemblies” are the individual devices within the controlgear (e.g. motor starters,
circuit breakers etc.)
2 “Controlgear” is also known as “Motor Control Centers”

BACKGROUND
The expectation within the company, and industry, is that when an electrical circuit breaker is
padlocked in the OFF position, the circuit breaker can not be closed unless there is a deliberate
intent to defeat this mechanism. This is the basis of any red tag/lock-out procedure. Most
manufacturers standard controlgear design is based upon this concept. There are a few designs
where this is not the case (i.e. the subject ABB controlgear). Knowing this, the Saudi Aramco
material standard (16-SAMSS-503) describes the functional requirements of the breaker
operating/padlocking mechanism to ensure S. Aramco’s expectation is achieved.
All the Center 5000 equipment, supplied to S. Aramco since 1994 does not have the
necessary modification, required to comply with the safety requirements of the
specification.

RECOMMENDATIONS
The manufacturer can modify the equipment at the site. The fix is relatively simple but
will require that each individual switching assembly be de-energized and removed for
the repair. Contact Shukri Harb, ABB Regional Marketing & Sales Manager, L.V.
Switchgear, Al Khobar. Tel: 898-5234/898-5750. Fax: 894-6970.
Note: This may be a potential problem with any 480V controlgear with the circuit
breaker operating handle mounted on the compartment door. It is recommended that
whoever surveys the plant to identify the above problem also keep alert to other similar
equipment that may have the same problem.
Contact Ron Carlson at 874-6128, email: carlsorw@aramco.com.sa with any questions.

_________________________
R. N. SEALY, Manager (A)
Consulting Services Department