Maintenance · Free Template

Safety Bypass and Override Register Template

A register of active and closed bypasses, inhibits and overrides on trips, interlocks and alarms. It shows how long each bypass has been in place and flags bypasses past their planned removal date.

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How to Use sheet with steps
Template sheet, blank and ready
Example sheet, filled in
126 built in formulas
A4 landscape print setup
Works in Excel, Google Sheets and LibreOffice

Preview of the Filled Example

This is the Example sheet from the download, so you can see exactly how the completed safety bypass and override register looks.

Plant / unitBoiler house

Maximum days without review7

ProcedureBypass procedure BP 001

Bypasses and overrides

Tag / function	Description	Reason	Applied	Planned removal	Removed	Days open	Compensating measures	Approved by	Status	SIS?
PSHH 1101	Steam header HH trip	Transmitter replacement	22 Oct 2026	25 Oct 2026		2	Operator at panel, PT 1101 B/C in 1oo2	Area authority	Open	Yes
LAL 4102	Tank low level alarm	Faulty switch	12 Oct 2026	19 Oct 2026		12	Hourly field check of level	Shift supervisor	OVERDUE	No
XV 4101 PST	Partial stroke test inhibit	Valve maintenance	04 Oct 2026	09 Oct 2026	08 Oct 2026	4	Valve locked open	Area authority	Closed	Yes

Active bypasses:2 · Overdue:1 · SIS bypasses active:1

About the Safety Bypass and Override Register

Bypassed trips are one of the most common contributors to process incidents, because a forgotten bypass leaves a hazard unprotected. A visible register with approvals, compensating measures and overdue flags keeps every bypass under control.

How to fill in this template

Add a row as soon as a trip, alarm or interlock is bypassed, with the reason, approval and compensating measures.
Set a planned removal date.
Enter the removal date when the bypass is taken off; status changes to Closed.
Review the register every shift: OVERDUE and REVIEW items need action.
Long or repeated bypasses should be raised as an MOC.

What the formulas do

Days open = today (or removal date) − applied date.
Status: Closed when removed; OVERDUE after the planned removal date; REVIEW when open longer than the review limit; otherwise Open.

Frequently Asked Questions

What is a compensating measure?

A temporary measure that provides protection while the bypass is in place, such as an operator watching a backup reading or a valve locked in a safe position.

Who should approve a bypass?

An authorised person defined in the bypass procedure; SIS bypasses normally need a higher level of approval.

When does a bypass need an MOC?

When it stays in place beyond the time allowed by the procedure or becomes a long term change.

Learn more on the blog

What is SIL (safety integrity level)

A practical guide on instrumentationblog.in that explains the procedure behind this template and how engineers apply it on real plants.

Read Full Article

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