Stationary Ammonia Operator

Position Summary

The Stationary Ammonia Operator is responsible for the safe, efficient, and code-compliant operation of industrial ammonia refrigeration systems at a distribution center or ammonia plant in the State of Texas. This position requires comprehensive knowledge of ammonia refrigeration mechanics and full compliance with Federal OSHA Process Safety Management regulations (29 CFR 1910.119), EPA Risk Management Program requirements (40 CFR Part 68) as administered in Texas by the TCEQ under the Texas Clean Air Act, TCEQ air permit requirements under 30 TAC Chapter 106, ASHRAE Standard 15, and IIAR standards. The operator shall maintain meticulous inspection and maintenance records meeting both federal and Texas state requirements and must be prepared to respond to OSHA Region VI or TCEQ compliance inspections.

Minimum Qualifications

Education & Certification

• High school diploma or GED required; Associate’s degree in HVAC/R, Mechanical Technology, or related field preferred
• EPA Section 608 Universal Certification — required by federal law for handling regulated refrigerants
• RETA CARO (Certified Assistant Refrigeration Operator) or CIRO (Certified Industrial Refrigeration Operator) preferred
• OSHA 10-Hour or 30-Hour General Industry certification preferred (Federal OSHA standards apply in Texas)
• TDLR ACR Contractor License (Class A — Process Cooling) preferred if performing maintenance/repair work not covered by the industrial exemption; or verification that the industrial-operation exemption under Texas Occupations Code §1302.052 applies to the position
• Hazardous Materials First Responder — Operations Level (29 CFR 1910.120 / NFPA 472) or higher
• Valid Texas driver’s license
• If working within the City of Houston: Stationary Engineer’s License (applicable grade) as required by Houston city ordinance

Experience

• Minimum 2–5 years of experience operating industrial ammonia refrigeration systems
• Experience in cold storage, food processing, or distribution center environment preferred
• Demonstrated working knowledge of OSHA PSM (29 CFR 1910.119) and EPA RMP (40 CFR Part 68) compliance
• Familiarity with TCEQ permit requirements under 30 TAC Chapter 106 preferred

Knowledge, Skills & Abilities

• Thorough understanding of the anhydrous ammonia refrigeration cycle, thermodynamics, and system components
• Ability to read and interpret P&IDs, mechanical drawings, equipment manuals, and TCEQ permit documents
• Proficiency with CMMS (Computerized Maintenance Management Systems) and digital log-keeping
• Strong written and verbal communication for operator logs, TCEQ PBR recordkeeping, and incident reporting
• Ability to work rotating shifts, weekends, holidays, and on-call as required
• Physical ability to wear full PPE including SCBA, Level B chemical suit, and perform confined space entry

General Duties & Responsibilities

• Operate, monitor, and control all ammonia refrigeration equipment including compressors, condensers, evaporators, pressure vessels, accumulators, pumps, and auxiliary systems
• Maintain system pressures, temperatures, and refrigerant charge within design specifications
• Monitor and respond to system alarms, abnormal readings, and emergency conditions at all hours
• Maintain accurate operator logs and inspection records compliant with OSHA PSM (29 CFR 1910.119), EPA RMP (40 CFR Part 68), and TCEQ 30 TAC §106.8 rolling 12-month recordkeeping requirements
• Maintain on-site TCEQ Permit by Rule (PBR) compliance records under 30 TAC §106.373 and/or §106.477 and make available for immediate inspection upon TCEQ request
• Adhere to PSM/RMP Program Management of Change (MOC) procedures for any system modifications
• Coordinate with contractors and vendors; verify contractor personnel hold required TDLR licenses or qualify under the industrial exemption
• Participate in emergency response planning, drills, and incident investigation
• Maintain OSHA 300/300A logs as required under 29 CFR 1904 (federal recordkeeping applies in Texas)
• Support all EHS programs including Hazard Communication (29 CFR 1910.1200 HazCom), LOTO (1910.147), confined space (1910.146), and hot work permitting
• Promptly report any ammonia releases to the TCEQ as required under Texas Health and Safety Code Chapter 382 and TCEQ emergency notification rules; notify the National Response Center (NRC) for releases above RQ (100 lbs NH₃) as required under CERCLA
• Complete all required training and maintain current certifications

Daily Inspection & Maintenance Duties

Performed each operating day; results recorded in operator log. Regulatory basis: IIAR 6-2019, OSHA 29 CFR 1910.119, TCEQ 30 TAC §106.373/§106.8 rolling compliance records.

Ammonia System Operations (Daily)

• Record all compressor suction/discharge pressures, temperatures, oil levels, and amp draws in the operator log
• Inspect compressors for unusual vibration, noise, leaks, or overheating; check crankcase heaters
• Verify condenser fan/pump operation; inspect evaporative condenser basin water level and chemical treatment
• Check high-side and low-side vessel liquid levels (receivers, accumulators, intercoolers)
• Inspect all safety relief valve (PRV) discharge piping for frost, moisture, or signs of weeping
• Test operation of oil separators and oil pots; drain oil as needed
• Inspect all visible ammonia piping, fittings, and valves for frost, ice, or visible leaks
• Verify all ammonia gas detection/alarm systems are operational; confirm sensor readings are within calibration range
• Check all automated controls, setpoints, and HMI/SCADA system for active faults or alarms
• Perform portable gas detector sweep of engine room at start of each shift
• Verify all PPE (SCBA, gas masks, chemical suits, gloves, face shields) is staged, accessible, and serviceable
• Document all readings, observations, and corrective actions in the daily operator log; retain for TCEQ/OSHA compliance

Distribution Center Maintenance (Daily)

• Inspect refrigerated dock doors, dock levelers, and dock seals for air infiltration or damage
• Walk all refrigerated spaces; verify temperature setpoints are maintained in each zone; document readings
• Check walk-in cooler/freezer temperatures and defrost cycle operation
• Inspect unit coolers (evaporator coils) for ice buildup, proper drainage, and fan operation
• Confirm operation of door heaters, anti-sweat heaters, and floor heating systems
• Inspect and clear floor drains in refrigerated areas to prevent blockage and ice formation
• Review prior shift logs for outstanding work orders, alarms, or deferred maintenance items
• Communicate with warehouse supervision regarding temperature or equipment concerns affecting product integrity

Weekly Inspection & Maintenance Duties

Performed weekly; documented in operator log. Regulatory basis: IIAR 6-2019, OSHA 29 CFR 1910.119, TCEQ 30 TAC §106.8 rolling 12-month compliance records.

• Test operation of all high-pressure and low-pressure cutouts on each compressor; document results
• Inspect and exercise all manual shut-off valves; lubricate valve stems as required
• Inspect compressor coupling alignment and belt tensions; check for unusual wear patterns
• Lubricate compressor shaft seals, bearings, and manufacturer-specified lubrication points
• Inspect and record condenser coil cleanliness; water-wash or brush-clean fouled sections
• Check cooling tower / evaporative condenser water treatment chemistry; add chemicals as required
• Verify proper operation of all solenoid valves, check valves, and thermostatic/electronic expansion valves
• Test battery backup and UPS systems for control panels
• Inspect all electrical panels, junction boxes, and motor starters for overheating or damage
• Perform calibration check on ammonia detector sensors; document readings; flag out-of-tolerance sensors
• Test audio/visual alarms for engine room, dock areas, and occupied spaces
• Inspect all eyewash stations and safety showers for adequate flow and cleanliness (OSHA 29 CFR 1910.151); record inspection date on tag
• Check all fire extinguisher inspection tags in mechanical areas
• Review and update outstanding CMMS work orders

Monthly Inspection & Maintenance Duties

Performed monthly; documented. Regulatory basis: IIAR 6-2019, OSHA 29 CFR 1910.119, EPA 40 CFR Part 68, ASHRAE Standard 15, TCEQ 30 TAC §106.373/§106.477.

• Perform full compressor oil analysis; change oil per manufacturer schedule or analysis results
• Change oil filters and refrigerant oil separator elements per differential pressure or schedule
• Inspect and clean compressor oil coolers; verify oil cooling system operation
• Megger test compressor motors; record insulation resistance values and compare to baseline
• Calibrate ammonia gas detectors using certified calibration gas per manufacturer instructions; record results in compliance log required under TCEQ 30 TAC §106.8
• Test and document operation of all emergency shutdown systems (ESD) including manual pull stations
• Inspect all pressure gauges and thermometers; replace any that are damaged or out of tolerance
• Inspect all suction piping, vessel, and fitting insulation; repair damaged sections to prevent condensation and corrosion
• Verify hot gas defrost or electric defrost systems on all evaporator coils are operating correctly
• Inspect and tighten all electrical connections in motor control centers (MCC) and control panels
• Perform functional test of all automated purgers; record non-condensable gas purge volumes
• Review and update Process Safety Information (PSI) documents for accuracy; note any required updates through MOC process
• Conduct monthly EHS/safety meeting with operations team; document attendance and topics
• Verify all required operating permits, TDLR licenses (for any maintenance contractors on site), and TCEQ PBR records are current and properly maintained on site
• Inspect all confined space entry equipment (ventilation blowers, gas monitors, retrieval systems, harnesses)
• Review OSHA 300 log entries for the month; ensure timely and accurate recording

Quarterly Inspection & Maintenance Duties

Performed every three months; documented. Regulatory basis: IIAR 6-2019, OSHA 29 CFR 1910.119, EPA 40 CFR Part 68, TCEQ 30 TAC Chapter 106.

• Perform full preventive maintenance (PM) on all compressors per manufacturer’s PM schedule
• Inspect valve plates, piston rings, and cylinder walls (reciprocating compressors)
• Check screw rotor clearances and timing gears (screw compressors)
• Inspect and replace filter driers and strainers as needed
• Conduct full operational test of the site Emergency Response Plan (ERP); document results; share findings with local LEPC (Local Emergency Planning Committee) as required under EPCRA
• Test and certify all pressure relief valves (PRVs) per IIAR 6 Section 6 / ASME Code; replace any that fail seat testing; update PRV maintenance log
• Inspect all pressure vessels externally for corrosion, pitting, or mechanical damage; document with photographs
• Perform vibration analysis on all rotating equipment; compare to baseline trends
• Verify refrigerant inventory and reconcile with PSM/RMP records and TCEQ compliance records; report any unexplained losses immediately per TCEQ and CERCLA reporting obligations
• Conduct Mechanical Integrity (MI) inspection of piping systems per IIAR 6 and OSHA PSM 29 CFR 1910.119(j)
• Review and update P&IDs for any changes made during the quarter per MOC procedures
• Audit PSM/RMP documentation for completeness; update operating procedures as needed
• Test and verify all process safety instrumentation (PSVs, PSHs, PSLs, TSHs)
• Inspect cooling tower/evaporative condenser for biological growth, scaling, and structural integrity
• Conduct quarterly ammonia emergency response drill; document and file drill report; provide copy to EHS manager for LEPC coordination

Semi-Annual (Bi-Annual) Inspection & Maintenance Duties

Performed every six months; documented. Regulatory basis: IIAR 6-2019, OSHA 29 CFR 1910.119, EPA 40 CFR Part 68, ASME B31.5, TCEQ 30 TAC §106.373.

• Comprehensive inspection of all pressure piping systems under ASME B31.5 and IIAR 6 Mechanical Integrity requirements
• Ultrasonic thickness (UT) testing on identified high-priority piping circuits
• Visual inspection of all pipe supports, hangers, and expansion loops
• Inspection of insulated piping for moisture ingress or corrosion under insulation (CUI)
• Full operational test of all emergency isolation valves (EIVs) including automated and manual types; document results
• Calibrate and certify all safety instrumentation (pressure switches, temperature switches, level switches) with calibration records retained in the on-site TCEQ compliance file
• Conduct Hazard Identification (HAZID) walkthrough with EHS and Operations; document findings and corrective actions
• Review and update the Emergency Response Plan (ERP); coordinate with local LEPC and Texas Division of Emergency Management (TDEM) as applicable
• Test and verify all SCBA units; recharge cylinders and replace components per manufacturer interval
• Perform thermographic (infrared) scan of all electrical panels, MCC, and motor connections; document findings
• Inspect and test all electrical grounding connections and bonding straps on vessels and piping
• Review contractor compliance: verify all outside service vendors performing work on ammonia systems hold required TDLR ACR licenses or qualify under the industrial exemption
• Conduct an internal PSM compliance audit per OSHA 29 CFR 1910.119(o); document findings and corrective actions; retain records on site
• Review TCEQ PBR compliance records for the prior 6 months for completeness and accuracy
• Review employee training records; schedule refresher training as needed

Annual Inspection & Maintenance Duties

Performed annually; documented. Regulatory basis: OSHA 29 CFR 1910.119 (PSM), EPA 40 CFR Part 68 (RMP), IIAR 6-2019, ASME Section VIII, ASME B31.5, ANSI/IIAR 2, Texas Health and Safety Code (THSC) Chapter 382, TCEQ 30 TAC Chapter 106, EPCRA Section 312, CERCLA.

Pressure Vessel & Mechanical Integrity

• Coordinate and oversee annual inspection of all ASME-coded pressure vessels by a National Board-certified inspector (NBI) per NBIC NB-23
• Internal inspection of all vessels opened for maintenance
• External inspection and documentation of vessel nameplates, NB numbers, and MAWP ratings
• Hydrostatic or pneumatic testing as required by inspector findings
• Replace pressure relief valves (PRVs) per IIAR 6 scheduled replacement program (typically 5-year cycle unless testing program is established); coordinate with annual inspection
• Full NDE (non-destructive examination) of identified piping circuits per IIAR 6 Mechanical Integrity program

Federal PSM / EPA RMP Compliance (Applicable in Texas)

• Conduct or coordinate tri-annual Process Hazard Analysis (PHA) revalidation per OSHA 29 CFR 1910.119(e); document all findings and recommendations
• Complete annual compliance audit of PSM program per 29 CFR 1910.119(o); prepare written report for management
• Submit or update EPA Risk Management Plan (RMP) as required under 40 CFR Part 68; RMP submissions in Texas are coordinated through EPA Region 6; certify all RMP data for accuracy
• Update Process Safety Information (PSI) package including P&IDs, equipment specifications, SDS, and design data
• Complete annual review of all written operating procedures per 29 CFR 1910.119(f); certify current and accurate
• Audit Mechanical Integrity (MI) program documentation including all inspection records, test results, and corrective action logs
• Verify all Incident Investigation reports from the prior year are completed and corrective actions closed per 29 CFR 1910.119(m)

Training & Emergency Preparedness

• Coordinate annual ammonia emergency response training for all affected employees per OSHA 29 CFR 1910.119(h) and EPA 40 CFR §68.54
• Conduct annual full-scale ammonia emergency response exercise; invite local fire department and LEPC to participate as part of Texas LEPC coordination requirements under EPCRA
• Verify all operator certifications and licenses are current; submit renewal applications; retain copies in personnel training file
• Review and certify all confined space entry permits and rescue procedures per OSHA 29 CFR 1910.146
• Conduct annual Lockout/Tagout (LOTO) program audit per OSHA 29 CFR 1910.147
• Post annual OSHA 300A Summary of Work-Related Injuries and Illnesses from February 1 through April 30 per 29 CFR 1904.32 (federal OSHA recordkeeping applies in Texas)

Working Conditions & Physical Requirements

• Work in cold environments (below 32°F / 0°C) for extended periods in refrigerated spaces
• Work in hot environments in engine rooms and on rooftops (condenser access), including Texas outdoor summer heat (temperatures may exceed 100°F); heat illness prevention program required per OSHA and Texas climate considerations
• Ability to lift and carry up to 50 lbs; climb ladders, work at heights, and in confined spaces
• Required to wear full PPE including SCBA, Level B chemical resistant suit, face shields, and gloves
• Rotating shifts including nights, weekends, and holidays; on-call availability required
• Exposure to anhydrous ammonia (NH₃) hazards requires strict adherence to all safety protocols at all times