excellence in Dependable Automation

The Alarm Shelving eBook

1
Alarm Shelving.

2
Table of Contents
01: Introduction 4

02: Defining Nuisance Alarms 5

03: Why Nuisance Alarms Undermine Operator Situation Awareness 7

04: How Alarm Shelving Reduces Nuisance Alarm Fatigue 9

05: Answers to Common Concerns about Alarm Shelving 11

06: Alarm Shelving Guidelines for Your Alarm Philosophy 13

07: Alarm Shelving Functionality and Display Requirements (ISA-18.2) 15

08: Overview of Alarm Shelving Functionality in Common Control Systems 18

09: Conclusion 25

10: References 26

excellence in Dependable Automation

01: Introduction

In an ideal world, every control system alarm would indicate a COMMON CONTROL SYSTEM VENDORS
malfunction or abnormal condition that required operator action.
In reality, alarms that are irrelevant or annunciate excessively—
ABB System 800xA
otherwise known as nuisance alarms—pop up from time to time.
They pose a risk to successful operation of the plant because they Emerson Delta V

overload operators with nonessential noise and desensitize them to

Honeywell Experion
the importance of alarms (“I can ignore this alarm because I know
nothing will happen”). Rockwell Plant PAx

Siemens PCS 7
Alarm shelving provides a way for the operator to manage these
Yokogawa Centum with CAMS
nuisance alarms safely and securely. In fact, it is such an important
Schneider
tool for alarm handling that it is now required control system
functionality per ISA-18.2-2016 and IEC 62682 (Management of
Alarm Systems for the Process Industries).

In this ebook, we will address the benefits of implementing alarm

Definition: Alarms
“Audible and/or visible means of indicating to
shelving, address common alarm shelving concerns, discuss the the operator an equipment malfunction, process
deviation, or abnormal condition requiring a timely
considerations for implementing shelving effectively, and compare response” (ISA-18.2, IEC 62682)
important features provided by common control systems.

4
02: Defining Nuisance Alarms
Nuisance alarms do not behave like true alarms. Instead, they may not...

• Indicate a malfunction or abnormal condition

• Require an operator corrective action
• Return to normal (clear) after the operator’s response

Type of Nuisance Alarm What It Does Additionally, nuisance alarms clutter the alarm summary and
Chattering Alarm Repeatedly transitions between active state process graphic displays, making it harder for the operator
and inactive state in a short period of time to detect when a new alarm has occurred. This information
(e.g., three times in one minute). overload causes operators to lose their sense of situation
Fleeting Alarm Same as Chattering Alarm, except it does not awareness, which compromises the effectiveness of the alarm
repeat rapidly.
system. This “alarm fatigue” will cause even the most vigilant
Stale Alarm Remains annunciated (in alarm) for an
operator to become desensitized to true alarms, increasing
extended period of time (e.g., 24 hours).
the likelihood that a problem will be misdiagnosed—or, worse,
“Bad Actor” Is one of the top ten or twenty most
frequently occurring alarms. ignored altogether.

Alarm Performance Metrics

Based upon at least 30 days of data
Metric Target Value
Quantity of chattering Zero, action plans to correct any that occur.
To reinforce the importance of minimizing nuisance and fleeting alarms
alarms, the ISA-18.2 and IEC 62682 standards provide Stale alarms Less than 5 present on any day, with action
recommended performance metrics. plans to address
Percentage contribu- ~<1% to 5% maximum, with action plans to
tion of the top 10 most address deficiencies.
frequent alarms to the
overall alarm load

5
 Community
Emergency Response
FIC
Plant
Mitigation

PRV
Emergency Response

Passive Protection
Loss of Containment (e.g. Bund/Dike)
LSHH
CHEMICAL = A
Active Protection MATERIAL = B

Incident (e.g. Relief valve/Rupture disk) LAH

PRESSURE = X
LSH TEMP. = Y
VOLUME = Z
Safety Instrumented System
Trip

Operator Intervention
Prevention

Alarm

Loop Process Control

Process Value Process Design

Key takeaway: If you allow nuisance alarms to persist, you are compromising the reliability of the operator’s response to
an alarm. If you are claiming an alarm as a layer of protection or a safeguard, it may not work when needed, potentially
leading to an incident or additional demands on a safety instrumented system (SIS). Thus, you should not “take credit”
for alarms if you have significant nuisance alarm issues.

6
03: Why Nuisance Alarms Undermine
Operator Situation Awareness
Good process plant operators have keen situation awareness (SA), which is the ability to perceive, comprehend, and
anticipate changes in one’s environment. A high level of awareness helps them accurately observe alarm events, as well
as understand the full meaning and impact of those alarms in both the present and future.

However, this ability can be undermined by various factors, which are dubbed SA demons3,4

1. Attention tunneling: Focusing on one area or issue to an extent that alarms from
another area or issue are ignored.
2. Misplaced salience: Incorrect alarm priority or HMI representation of alarm importance
and other status information.
3. Errant mental models: Incorrect interpretation of what an alarm indicates or
mistakenly ignoring relevant alarms.

Moreover, signal detection theory quantifies an operator’s ability

to discern between useful patterns that provide information and
random patterns that distract from necessary information—i.e.,
It does not take a high nuisance
noise. As noise increases, the operator’s ability to discriminate a alarm rate for the operator to doubt
true alarm from a false alarm decreases. As little as a 25% false- the veracity of the alarm system5.
alarm rate is enough for operators to stop relying on the system to
detect an abnormal event3.

7
Why Do Operators Ignore Alarms?
There are numerous examples of where
the ignoring of nuisance alarms led to a
process safety incident3. An operator’s
reluctance to respond immediately to a
system that produces many false alarms
is a rational and expected behavior,
because responding takes time and
attention away from other important
tasks4. Therefore, the best way to reduce
human error in alarm management is to
eliminate nuisance alarms.

Alarm shelving provides a means for

reducing the impact of a nuisance alarm
until it can hopefully be addressed.

8
04: How Alarm Shelving Reduces
Nuisance Alarm Fatigue
Alarm shelving enables operators to temporarily remove nuisance alarms until the underlying problem can be addressed.

Alarm shelving is…

»» Temporary
»» Different from disabling the alarm
»» A safe and secure way to suppress an alarm
»» A form of alarm suppression initiated and controlled by the operator

The alarm is temporarily moved from the alarm summary display to a shelved
alarm display, otherwise known as a “shelf.” It stays on this shelf until it is Shelved alarms are
cleared by the operator, or when the maximum shelving time period is reached.
It is also tracked in the system. configured to return
after a designated
Alarm shelving is different than disabling or deactivating the alarm, which would
need to be tracked outside of the system and is more likely to be forgotten.
period of time.

Remember: Alarm shelving does NOT disable or deactivate the alarm

9
There are two types of alarm shelving, and each handle nuisance alarms
differently. Some control systems provide both types, while others support
just one type (continuous).

Shelving Type Behavior (If the alarm clears and re-annunciates within the shelving time period…) Best for

Continuous Shelving It will automatically be re-shelved without Chattering Alarms, Fleeting Alarms
additional action by the operator.

One-Shot Shelving The new alarm instance will be displayed to the op- Stale Alarms
erator and must be re-shelved.

10
05: Answers to Common Concerns about
Alarm Shelving
1. “Our operators cannot be trusted with alarm shelving.”
We trust operators to monitor and control critical processes with expensive equipment and to make the correct
decision when something goes wrong. So why wouldn’t we trust them to use alarm shelving appropriately? All you
need to do is train your operators on the importance of alarm shelving, when to use it, and proper procedures.

2. “Our operators will miss important alarms if we shelve them.”

The purpose of alarm shelving is to temporarily hide nuisance
alarms. This keeps operators from becoming desensitized to Definition: Alarm Rationalization
important alarms without disabling them altogether. Shelved The process of reviewing alarms to ensure
alarms are automatically unshelved after a designated period necessity, assign priority, and document the
of time (typically on the order of hours). rationale (i.e., cause, consequence, corrective
action, time to respond).
3. “Operators will forget which alarms are
suppressed.”
To ease concerns about forgetting suppressed alarms,
operators and managers should regularly review the alarms
on the suppressed alarm list, especially prior to equipment startup and during shift changes.

11
4. “Alarm shelving will enable our operators to continue ignoring the alarms
instead of addressing the issue.”
With training, operators will learn the correct protocol when they shelve an alarm, such as creating a
maintenance work order. To ensure these alarms are not being ignored indefinitely, management should regularly
review shelved alarm reports and ensure that the underlying issues are being corrected in a timely fashion.

5. “We do not need alarm shelving if we perform alarm rationalization or dynamic

alarming.”
Alarm rationalization and dynamic alarming work well for
expected situations. However, nuisance alarms develop Definition: Dynamic Alarming
for scenarios outside of rationalization, such as sensor The automatic modification of alarm
malfunctions, process changes, and severe weather attributes based on process state or
conditions. conditions.
Nuisance alarms cannot be avoided, and alarm shelving will
help plant safety by keeping this nonessential information
from desensitizing your operators to the importance of
alarms.

12
06: Alarm Shelving Guidelines for Your
Alarm Philosophy
Once you’ve decided to move forward with alarm shelving, you need to create guidelines and
add them to your alarm philosophy.
Your alarm shelving guidelines should clarify the following:

1. Which alarms can be shelved? Which cannot?

What is an Alarm Philosophy?
2. What is the maximum number of alarms that Guidelines that establish how your firm handles
all aspects of alarm management, from alarm
can be shelved at one time? criteria, prioritization, and classification, as well
as Management of Change (MOC).
3. What are your shelving procedures?
»» What is the authorization, reauthorization, and
approval process to allow an alarm to be shelved?
»» When should alarms be unshelved?
»» Should an approval process take place before
extending the shelf time?
»» When are interim alarms required, and what is the
procedure for use?
»» What action should the operator take after the
Per IEC 62682, operators should
alarm is shelved (e.g., write a work order, contact record the reasons for shelving
maintenance)?
alarms that extend beyond a single
»» When is MOC authorization required?
operating shift.

13
4. What type of training will be provided to operators to learn the correct alarm shelving procedures?
5. What action should be taken upon discovery of operator misuse of alarm shelving?

Alarm Shelving Best Practices

»» Train your operators on the purpose of alarm
shelving, when to use it, and proper protocol
»» Ensure your operators always have easy access to
the list of shelved alarms
»» Make it standard procedure for operators to review
the shelved alarm list during shift handover
»» Ensure that action is taken to address alarms on
the shelved alarm list; the number of alarms on the
shelved list should not continue to grow
»» Review shelving reports regularly to identify
unauthorized shelving, as well as which alarms are
being shelved and how often (most control systems
provide this capability)

14
07: Alarm Shelving Functionality and
Display Requirements (ISA-18.2)
The ISA-18.2 and IEC 62682 alarm management standards define requirements and recommendations for alarm
shelving functionality.

The following information can be used as a checklist to help evaluate and leverage the functionality provided by your
control system supplier.

Alarm Shelving Functionality (ISA-18.2-2016)

Function Required (REQ) or Recommended (REC)

q the ability to shelve alarms REQ

q displays of shelved alarms, or equivalent list capabilities to indicate all REQ
alarms shelved
q a time limit for shelving (time limit is a function that unshelves the alarm REQ
when the time period expires)
q access control for shelving of individual alarms REQ
q the ability to unshelve alarms REQ
q a record of each alarm shelved REQ
q prevent alarm floods when active alarms are automatically unshelved REC

15
Information to be shown in a Shelved Alarm Display (ISA-18.2-2016)

Information Required (REQ) or Recommended (REC)

q tag name for alarm REQ

q tag description or alarm description for alarm REQ
q alarm type REQ
q the alarm status (i.e., active or not active) REQ
q the ability to unshelve alarms REQ
q the alarm priority REQ
q the shelved time remaining or the time and date the alarm was shelved. REQ

16
Functionality of a Shelved Alarm Display (ISA-18.2-2016)

Function Required (REQ) or Recommended (REC)

q sorting of alarms by chronological order of shelving or shelved time remaining REQ

q sorting of alarms by priority REQ
q individual unshelving of alarms REQ
q sorting of alarms by tag REC
q filtering of alarms by priority REC
q filtering of alarms by alarm state REC
q filtering of alarms by process area REC
q operator entry of the reason the alarm was shelved REC
q group unshelving of alarms REC
q navigational link to a process display REC
q navigational link to the tag detail display REC

17
08: Overview of Alarm Shelving
Functionality in Common Control Systems
Alarm shelving is an important alarm handling tool
for the operator. As a result of the adoption and
promulgation of the ISA / IEC alarm management
standards, control system suppliers have enhanced
their offerings to provide alarm shelving as a core
function in the control system. Each supplier has
implemented suppression functionality differently.
The following section provides an overview of shelving
functionality for several of the most common control
systems.

If your control system is not discussed, then please

consider reaching out to your supplier to learn more.
In fact, even if your system is discussed, you should
treat this as an introduction and prompt for follow-up
questions for your supplier.

18
ABB System 800xA
Continuous 3

One Shot 3

»» Shelving can be enabled / disabled for the system

»» When shelving an alarm, the operator can select from predefined shelving period (2 hours is the default).

»» Maximum shelving time period

can be defined for the system.
It can be set to ∞ (i.e., no time
limit).

»» When shelving an alarm, the

operator can document the
reason for shelving by selecting
from a list of predefined
reasons.

»» Operator selects type of

shelving (i.e., continuous or
one-shot).

»» Operator can enter an optional

free-form comment to provide
additional information.

»» Alarm bands on process graphics indicate whether there any shelved alarms in a particular process area.

»» Can be defined to require no authentication, operator authentication, or authentication by operator and supervisor (dual signature).

19
Emerson DeltaV
Continuous 3

»» Each alarm has an individually configurable alarm shelving time period (in engineering
mode).

»» Maximum shelving time period for an alarm is 999 days.

»» Default shelving time period is 8 hours.

»» Setting the shelving time period of an alarm to 0:0:0 D:H:M prevents the alarm from being
shelved.

»» In V12 and earlier, one form of manual suppression was available. It can be used for
shelving or out-of-service (long-term suppression) depending upon the value of the
shelving time period. In V13 and later, alarm shelving and out-of-service are separate and
independent functions.

»» Easy access to shelved alarm list.

»» Shelved alarm list displays time remaining until alarm comes off the shelf.

»» When shelving an alarm, the operator can document the reason for shelving by selecting
from a list of predefined reasons.

20
Honeywell Experion
Continuous 3

»» When shelving an alarm, the operator can document the reason for shelving by selecting from a list of predefined reasons.

»» For each shelving reason, a range of shelving time periods can be established, along with a default shelving time period.

»» The operator can enter the desired shelving time period based on the range associated with the shelving reason.

»» When shelving an alarm, the operator can enter an optional free-form comment to provide additional information.

»» Symbols on graphic display indicate both that alarm is shelved and the priority that alarm would be.

»» Alarm summary display indicates how many alarms are shelved.

Reason for Shelving Shelving Period Default Shelving Time Period Enter Comment (Detail Reason)
for Shelving)

Nuisance Alarm 30 mins - 8 hrs 2 hrs Yes

Standing Alarm 30 mins - 8 hrs 4 hrs Yes
Maintenance 30 mins - 1 wk 1 day Yes
Maintenance (Long Term) 30 mins - 3 wks 1 week Yes

21
Rockwell PlantPAx
Continuous 3

»» Alarm shelving can be enabled / disabled on an alarm-by-alarm basis.

»» A maximum alarm shelving time can be defined individually for each alarm (default is 8 hours).

»» When shelving an alarm, the operator can set the shelving duration to any time that is less than or equal to the maximum shelving time
defined for the alarm.

»» When shelving an alarm, the operator can enter an optional, free-form comment to document the reason for shelving.

»» Symbols on graphic display indicate that alarm is shelved (inhibited).

22
Siemens PCS 7
Continuous 3

»» Single setting to enable alarm shelving throughout the application.

»» Single setting for alarm shelving time that gets used for all alarms.

»» Maximum alarm shelving time is 9 days, 23 hours, and 59 minutes.

»» Operator has ready and easy access to the list of alarms that are shelved.

»» Separate Shelved alarm lists for

alarms that are shelved but not
active (List of messages to be
hidden) and those that are active
and shelved (Hidden List)

»» When shelving an alarm, the

operator can enter an optional,
free-form comment to document the
reason for shelving.

»» Separate list and clear difference from alarm out-of-service (Locking).

23
Yokogawa Centum with CAMS
Continuous 3

One Shot 3

»» Alarm shelving can be enabled / disabled on an alarm-by-alarm basis (SIS alarm has shelving
disabled by default).

»» When shelving an alarm, the operator chooses the maximum shelving time by dragging the alarm to
a shelving folder with a predefined timeout (e.g., 30 mins, 1 hour, 8 hours, or 24 hours).

»» Maximum time an alarm can be shelved is 24 hours.

»» Operator has ready and easy access to the list of alarms that are shelved.

»» Operator can unshelve any alarm at any time.

»» When shelving time has elapsed, the operator must manually unshelve the alarm by dragging it
back to the active alarm list.

»» Security & Access control can be used to manage which shelving times are selectable by the user.

24
09: Conclusion
Alarm shelving is an important tool for helping operators deal with nuisance alarms. Long-term exposure to nuisance alarms desensitizes
operators to the importance of alarms and causes them to distrust the control system.

Alarm shelving is also mandatory functionality to be provided by a control system, as defined in the ISA-18.2-2016 and IEC 62682 alarm
managements standards.

End users should explore the alarm shelving functionality provided by their supplier and establish a procedure that meets their operational
requirements. They should also be sure to put in place the checks and balances that ensure shelving is being used properly and that
underlying alarm issues are being addressed.

For more information on exida Alarm Management services visit exida.com/Alarm-Management

25
10: References
1
ANSI/ISA-18.2-2016. “Management of Alarm Systems for the Process Industries.”

2
IEC 62682:2014. “Management of alarm systems for the process industries.”

3
Dunn, D.G., et al, “When Good Alarms Go Bad: Learning from Incidents,” 70th Annual Instrumentation and Automation
Symposium, Texas A&M Univ. (Jan. 2015)

4
Endsley, M., “Designing for Situation Awareness: An Approach to User-Centered Design,” CRC Press, Boca Raton, FL
(2012).

5
Sands, Nicholas P., et al, “Plug the Holes in the Swiss Cheese Model,” Chemical Engineering Progress, an AIChE
publication (Sept. 2017).

26