Operations & Maintenance

Enhancing Industrial Safety: The Role of Technology in Managing Operational Risks 

In today’s rapidly evolving industrial landscape, ensuring the safety and efficiency of operations is more important than ever. A recurring theme in safety management is the challenge posed by bypasses and protection layer defeats, which affect the integrity of safety systems such as alarms and interlocks that prevent hazardous incidents.

These small, often overlooked actions can accumulate, leading to significant risks if not properly managed. Effective bypass management involves risk assessment, compensating measures and strong communication and documentation processes. This ensures safety and compliance with industry standards and avoids severe consequences.

A strategic approach to managing bypasses is essential for the safety and reliability of industrial operations. As we explore this topic, we look at how technology can transform these challenges into opportunities for improvement. 

Understanding the Risks: The Swiss Cheese Model 

The Swiss Cheese model, a metaphor in risk management, illustrates how layers of defense (like slices of Swiss cheese) have holes, and when these holes align, they can lead to catastrophic events. For example, if poorly maintained equipment wears down at the same time as safety systems malfunction, industrial settings may be exposed to immense accidents that threaten the safety of many. In industrial settings, bypasses—temporary overrides of safety systems—are akin to creating these holes. They might seem insignificant individually but can collectively increase the risk of failures.  

The Challenge of Data Silos and Manual Processes 

One of the fundamental issues in managing these risks is the existence of data silos. Different systems, such as fire control and detection systems, often operate independently, leading to communication gaps. For instance, in safety-critical environments, such as chemical plants, a lack of integration between alarm systems and emergency response protocols can delay incident response. If an alarm is triggered but not communicated to the emergency response team, the delay can exacerbate the situation and potentially cause shutdowns or evacuation. Manual processes, like logging information by hand, further complicate matters. Operators might bypass systems for practical reasons, but without proper tracking and communication, these actions can go unnoticed across shifts and teams. 

The Need for Traceability and Auditability 

Despite understanding the importance of traceability, many industries struggle with implementing effective solutions, because of lack of standardization, technological barriers, cost concerns, and overall resistance to change. The illusion of control is prevalent—believing that systems are managed simply because they haven’t failed yet. However, as industry reports like those from the Chemical Safety Board (CSB) show, these oversights can result in severe consequences. 

Embracing Digital Transformation 

Digital transformation offers a promising solution to these challenges. By integrating technology, industries can achieve better visibility of controls and management of bypasses with real-time information and data-driven decision-making from the field to the enterprise. For instance, PETRONAS, an oil and gas company, reduced its active bypasses by over 90% through digital solutions, highlighting the potential for significant improvements. 

Overcoming Resistance and Building a Safety Culture 

Adopting new technologies requires overcoming resistance and fostering a culture of safety. Many operators view safety systems as complex "black boxes" and hesitate to engage deeply with them. However, by interpreting these systems and demonstrating the value of digital tools, industries can equip their workforce to embrace change.

Technologies can streamline operations, automate routine tasks and reduce downtime. Advanced safety systems provide real-time data and analytics, enabling proactive identification and mitigation of risks. This provides operators and employees with a greater sense of satisfaction and ownership and inspires a culture of continuous improvement, leading to increased efficiency and productivity. 

The Path Forward: Operational Risk Management 

Ultimately, addressing bypasses and inhibits is part of a broader strategy of operational risk management. This involves understanding the "who, what, where, when, and why" of bypass actions and integrating this knowledge into a cohesive safety strategy. By doing so, industries can not only enhance safety outcomes but also improve operational efficiency and reliability. 

Conclusion: The Business Case for Safety Investments 

Investing in technology to manage bypasses is not just about compliance—it's about achieving better business outcomes, as improved safety leads to fewer disruptions, higher reliability and ultimately, a stronger bottom line.

As industries continue to evolve, embracing digital tools is essential for staying competitive and safe. Hexagon’s solutions— j5 Operations Management Solutions, AcceleratorKMS® and PAS PlantState IntegrityTM—integrate to offer a comprehensive approach to managing these challenges. PAS PlantState Integrity provides detailed insights into the application of bypasses, ensuring full traceability and auditability from a control system perspective, while AcceleratorKMS and j5 Operations Management Solutions facilitate effective communication and procedural adherence by allowing operators to log entries and create workflows that inform all stakeholders.

This interconnected approach ensures that every bypass and inhibit is justified and documented, enhancing overall safety and efficiency across facilities. Whether you’re looking to reduce bypasses or enhance your operational risk management strategy, watch the on-demand version of our webinar to guide you on this journey, offering actionable insights that can transform your operations, significantly reducing operational risks and improving safety outcomes.