š Bypassing Safety Devices. Why Itās Never āJust for a Minuteā
If youāve ever worked in a plant, you know there are moments where someone says: āLetās just bypass this to get through the job, itāll be fine.ā But hereās the thing⦠regulations, design intent, and real-world incidents all say otherwise. What ABSA and PESR Say In Alberta, ABSAās AB-528 User Guide makes it crystal clear: āSafety control functions shall be installed in such a way as to prevent a bypass.ā The Pressure Equipment Safety Regulation (PESR) goes further in Section 39, requiring that relief and overpressure protection systems remain sealed after maintenance, and that any change requires Safety Codes Officer approval. This isnāt just bureaucratic red tape, itās about preserving Independent Protection Layers (IPLs), which are often the only barriers between a process upset and a serious incident. What Counts as a Safety Control? According to ABSA, safety controls include instrumented and non-instrumented functions, like: - Shutdown & blowdown valves - Level, pressure, flow, or temperature safety trips - Burner management systems - Fire & gas detectors - Pressure safety valves, rupture disks, overspeed trips - HVAC pressurization in control rooms (Full list in ABSA Appendix A.) Bypassing any of these removes a critical safeguard. Global Industry Parallels In U.S. offshore operations, regulators (BSEE) allow temporary bypass only with strict controls: - Visual indication of the bypass - Continuous monitoring - Written, time-bound approvals Even then, itās treated as an exception, not a shortcut. The Real Question for Operators Weāve all seen it done, but the real measure of safety culture is how we manage it: ā
Do you have a formal bypass permit process? ā
Are bypasses tracked, tagged, and alarmed? ā
Is there a clear plan for restoration, and is it verified? ā
Do you know which alarms or trips are absolute ānever bypassā territory? š¬ Your Turn - Have you been part of a bypass management or rationalization process? - What worked, what didnāt, and what would you never skip? - How do you train new operators on the seriousness of bypassing safeguards?