Ammonia Refrigeration PSM Compliance Checklist

Are all engine room access points clearly marked with 'Anhydrous Ammonia - Authorized Personnel Only' signage?

Verify the engine room ventilation system is operational and providing adequate air changes per hour (min. 6 ACH). Check airflow with an anemometer.

Confirm the emergency shutdown (ESD) switch is easily accessible, clearly labeled, and functional. Test the ESD monthly and record results.

Check that ammonia sensors are properly calibrated (within the last 6 months) and positioned at appropriate locations (e.g., near potential leak sources, low points).

Inspect for any signs of ammonia leaks (odor, white vapor, oil spots) around flanges, valves, and equipment. Use an ammonia leak detector to verify.

Ensure adequate lighting (minimum 50 foot-candles) is provided throughout the engine room for safe operation and maintenance.

Verify the engine room is free of obstructions, debris, and combustible materials. Maintain clear walkways and access to equipment.

Confirm that appropriate warning signs (e.g., 'Danger - Anhydrous Ammonia', 'PPE Required') are prominently displayed.

Inspect the emergency eyewash station and safety shower for proper function (minimum 15 minutes of continuous flow). Ensure the water is tepid (60-100°F).

Verify the wind sock is in good condition and clearly visible to indicate wind direction in case of a release.

Visually inspect all ammonia piping for signs of corrosion, pitting, or thinning. Pay close attention to areas near welds and supports.

Verify that pipe supports are properly installed and maintained to prevent excessive stress on piping.

Inspect insulation on cold piping for damage or deterioration. Damaged insulation can lead to ice formation and corrosion under insulation (CUI).

Confirm that pressure relief valves (PRVs) are properly sized, installed, and have current certification tags. Verify discharge piping is directed to a safe location.

Inspect ammonia vessels (e.g., receivers, accumulators) for signs of bulging, dents, or other damage. Review vessel inspection records for compliance.

Operate critical valves (e.g., isolation valves, control valves) to ensure they function smoothly and do not leak. Lubricate valve stems as needed.

Check all flanged connections for leaks using an ammonia leak detector. Tighten bolts as necessary, following proper torque specifications.

Ensure that all equipment nameplates are legible and contain accurate information (e.g., pressure rating, serial number).

Verify oil pots on compressors are at the correct level and the oil is clean. Document oil changes.

Confirm the non-condensable gas purge system is functional and properly removing air from the system.

Verify that appropriate PPE (e.g., ammonia-rated respirators, gloves, eye protection, chemical suits) is readily available and in good condition.

Confirm that all personnel who may need to use respirators have been properly fit-tested within the last year.

Review the emergency response plan for ammonia releases. Ensure it is up-to-date and readily accessible.

Verify that first aid supplies specific to ammonia exposure (e.g., sterile saline solution for eye irrigation) are available.

Check that the communication system (e.g., radios, alarms) is functional and can be used to alert personnel in case of an emergency.

Ensure that evacuation routes are clearly marked and unobstructed.

Inspect fire extinguishers for proper charge and current inspection tags. Ensure personnel are trained in their use.

Verify that spill control materials (e.g., absorbent pads, neutralizing agents) are readily available in case of an ammonia release.

Confirm that emergency drills are conducted regularly (at least annually) to practice the emergency response plan.

Verify that contact information for the local HAZMAT team is readily available.

Verify that the PSM program is up-to-date and includes all required elements (e.g., process safety information, hazard analysis, operating procedures).

Review operating procedures for all phases of operation (startup, shutdown, normal operation, emergency operation). Ensure procedures are readily available to operators.

Inspect maintenance records for all critical equipment (e.g., compressors, pumps, valves). Verify that maintenance is performed according to schedule.

Verify that all personnel involved in the operation and maintenance of the ammonia refrigeration system have received adequate training. Review training records.

Review the most recent Process Hazard Analysis (PHA) for the ammonia refrigeration system. Ensure that recommendations from the PHA have been implemented.

Verify that a Management of Change (MOC) process is in place and followed for any changes to the ammonia refrigeration system.

Review the mechanical integrity program for the ammonia refrigeration system. Ensure that inspections and tests are performed according to schedule.

Verify that contractors working on the ammonia refrigeration system are aware of the hazards and have received appropriate training.

Confirm that a Pre-Startup Safety Review (PSSR) is conducted after any significant modifications to the ammonia refrigeration system.

Review incident investigation reports for any incidents involving the ammonia refrigeration system. Ensure that corrective actions have been implemented.