NH3 Training Centers of Texas, LLC presents

Process Safety Management & Risk Management Requirements for the Ammonia Refrigeration Industry


This training is designed as an introduction to EPA’s Risk Management Plan and OSHA’s Process Safety Management Program for the facilities PSM Team, Plant Management and Corporate personnel. It is a review of each of the 14 elements of PSM and the EPA RMP Requirements.

We believe that knowledge of the requirements of the regulations will help benefit the facility personnel in ensuring their program meets the required regulations.

Course Objective: Provide training to the PSM Team to ensure they understand the

requirements of OSHA PSM and EPA’s RMP Standard.

Course Content

Course will include the following:

(1)Overview of the RMP and PSM

  • Review of Regulatory Requirements
  • History for Releases that promoted the Regulatory Requirements
  • Refrigeration Equipment Components included in the RMP and PSM Program
  • Responsible personnel at the facility
  • The difference between the RMP and PSM Programs

(2) Risk Management Plan (EPA 40 CFR Part 68)

Overview of the Management System

  • Persons responsible for the Program Management
  • Organization Responsibilities

Hazard Review - Off-Site Consequence Analysis

  • Using RMP Comp for Worst Case and Alternative Case Scenario
    Determining the Population around facility
    Distance to End Point

Prevention Program

  • 14 Elements of OSHA Process Safety Management

Emergency Planning and Response

  • Emergency Action Plan
    Emergency Response Program Requirements
    Coordinating Drills

Submitting the RMP Submittal to the EPA

  • Setting up the Certifying Official and
  • Preparer with MyCDX
  • Process Inventory
  • Latitude and Longitude
  • Emergency Contact Information
  • Gathering the dates and information for the
  • RMP Submittal
  • Requirements for updated or corrections to the RMP Submittal

(3) Prevention Program (OSHA 1910.119 Process Safety Management Program

Employee Participation - OSHA 1910.119 (c)

  • Employee Involvement (From Production, Operations, Administration, Maintenace and Refrigeration Personnel)
  • Levels of Responsibility
  • Knowledge of PSM for all employees
  • Knowledge of the Ammonia Refrigeration System

Process Safety Information - Required Documentation - OSHA 1910.119 (d)

  • Piping and Instrumentation Diagrams (P&IDS)
  • Block Flow Diagrams
  • Equipment List
  • Desired System Operating Ranges
  • Safety Relief Calculations and Replacement Schedules
  • Ventilation System Capacity (Ventilation Calculations)
  • Equipment Installation, Operation and Maintenance Manuals (OEM’s)
  • Inventory Calculations (based on Vessel Levels)
  • Ammonia Delivery Log
  • Ammonia System Maintenance Logs –
  • Purging, Draining Oil, etc.
  • Manufacturer Data Reports for Pressure Vessels
  • Material and Energy Balances
  • Design Codes and Standards
  • Safety Data Sheets
  • PLC Controls Operations
  • Safety Systems and Their Functions

Process Hazard Analysis - OSHA 1910.119 (e)

  • Overview of OSHA’s Process Hazard Analysis Standard
  • PHA Methodology types
  • A review of the different types of PHA Software
  • Scheduling The PHA Team Sessions
  • Pre-Study Documentation required.
  • Following the Facilities PHA Procedures
  • Types of Risk Matrix to use and the importance of using the correct Risk Matrix
  • Leadership and Facilitator Skills
  • PHA Team Requirements
  • PHA Closing Meetings with PHA team and Senior Management including corporate personnel.
  • Tracking PHA Action Items to Closure

Operating Procedures for Ammonia Process Equipment - OSHA 1910.119 (f)

  • Table of Contents- Equipment List of SOPs needed.
  • Safe Work Practices – (Confined Space, Hot Work, LOTO, Line Break)
  • Overall System Operations
  • Oil Draining
  • Component SOP’s
  • Charging the system with Ammonia
  • IIAR-7 Formatting Templates

Training - OSHA 1910.119 (g)

  • Initial and 3-Year Refresher Training
  • RETA I and RETA II Operator Training
  • Training for Operators to the Level of Responsibility
  • Training Matrix Tables
  • Emergency Response Training
  • Small Releases vs Major Release and how to respond.

Contractor Program - OSHA 1910.119 (h)

  • List of Approved Ammonia Contractors
  • Annual Contractor Safety Awareness Training
  • Certificate of Insurance
  • Annual Review of Safety Performance and Programs
  • Annual Review of Contractors
  • Emergency Actions for Contractors
  • Injury and Illness Log

Pre-startup Safety Review - OSHA 1910.119 (i)

  • When is a PSSR Required?
  • Who should perform the PSSR?
  • Construction and Equipment is installed per
  • Design Specifications
  • Safety Procedures
  • Operating Procedures
  • Maintenance Procedures
  • Emergency Response Procedures
    Training personnel in the above

Mechanical Integrity (3 Separate Chapters) - OSHA 1910.119 (j)

Preventative Maintenance

  • IIAR-6 Preventative Maintenance Program Requirements (review)

Refrigeration Systems Safety Devices

  • Compressors Cutouts (High Discharge, Suction, Oil Differential, Motor Amps)
  • High Level Floats on Vessels (to prevent liquid ammonia from going back to the compressors)
  • E-Stop Switches
  • Emergency and Continuous Ventilation
  • Ammonia Detectors and Alarms (Turns on Ventilations, Shutdown Compressors, etc.
  • Emergency Shutdown Valves (ESD’s) Maintenance and Tagging, PIDs

Inspection and Testing

  • Common Mechanical Integrity Deficiencies
  • Missing Pipe Labeling and Valve Tagging
  • Required Signage on Machine Room Doors
  • E-Stop and Ventilation Switches on the outside of the main machine room door.
  • Missing plugs
  • Exposed Electrical
  • SRV’s out of Date

Quality Assurance of new components (New and Existing Facilities)

  • Introducing new components to the system
  • Quality of materials used suitable for ammonia.
  • Installation quality checks against IIAR-6
  • Pre-Startup Review for each new component


Refrigeration Systems Safety Devices

  • Compressors Cutouts (High Discharge, Suction, Oil Differential, Motor Amps)
    High Level Floats on Vessels (to prevent liquid ammonia from going back to the compressors)
  • E-Stop Switches
  • Emergency and Continuous Ventilation
  • Ammonia Detectors and Alarms (Turns on Ventilations, Shutdown Compressors, etc.
    Emergency Shutdown Valves (ESD’s)
  • Maintenance and Tagging, PIDs

Training for process maintenance activities.

  • Written Maintenance Procedures (SMP’s)
  • Maintenace Staff Training

Safe Work Practices - OSHA 1910.119 (k)

  • Hot Work
  • Confined Space
  • Line Break Permit
  • Power Equipment Permit
  • Lock-Out Tag Out

Management of Change Procedures - OSHA 1910.119 (l)

  • Minor Change
  • Major Change
  • Replacement in Kind

Incident Investigation Program

  • Nuisance Odor Logs
  • Incident Investigation Logs
  • Near Misses

Emergency Response Program
Ammonia Odor Investigation (small release)

  • Handheld Detector
  • Respirators
  • Fit Test
  • Responding to a large Releasee

Registration Information

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LIVE ON-SITE- 3- Day Training

Location: NH3 Training Center of Texas, LLC, Conroe, Texas


This training is LIVE and can be delivered:

At your facility location, at a Local Area Venue, or at the NH3 Training Center of Texas, LLC (Conroe, Texas) Scheduled Courses

Scheduled Session: August 5, 2024 – August 7, 2024

Training Schedule will be Monday – Wednesday 8AM-4PM (with an hour break for lunch)

No Classroom is limited to 10 participants. JSC may cancel this session if the participation goal isn’t met.

Paid Registration must be 6 weeks in advance to allow time for training materials to be compiled.

COST: 1050. Each student

Includes: Workbook, Powerpoint presentations, & test materials.

To Register for this course: Go to our website at: www.NH3TrainingCenter.com or email: Jet@NH3TrainingCenter.com or Call 936-230-4392.

To schedule a Training at your facility or other location

Email: Jet@NH3TrainingCenter.com

Call: 936-230-4392

Or click the button below

Introductory & Advance Training Courses for the Ammonia Refrigeration Industry to meet regulatory compliance guidelines.

Phone: (936) 230-4392

Email: Jet@NH3TrainingCenter.com

Located in Montgomery, Texas


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