Ammonia Awareness Training: 5-Day Comprehensive Safety Course

Course Overview

This intensive 5-day ammonia awareness training provides comprehensive knowledge of ammonia properties, hazards, safe handling practices, and emergency response procedures. Designed for workers in ammonia production, refrigeration, fertilizer manufacturing, and any facility handling anhydrous or aqueous ammonia, this course ensures workplace safety and regulatory compliance.

Target Audience: Plant operators, maintenance technicians, safety officers, emergency responders, supervisors, warehouse workers, refrigeration technicians, and anyone working near ammonia systems or storage facilities.

Course Objectives:

• Understand ammonia physical and chemical properties

• Recognize ammonia hazards and health effects

• Apply safe work practices and procedures

• Use personal protective equipment correctly

• Respond effectively to ammonia emergencies

• Comply with OSHA and EPA regulations

Day 1: Ammonia Properties and Hazard Recognition

Morning Session: Introduction to Ammonia

Understanding Ammonia Fundamentals

Foundation knowledge of ammonia characteristics:

Physical and Chemical Properties:

• Chemical formula: NH₃

• Colorless gas with pungent, suffocating odor

• Boiling point: -33.3°C (-28°F) at atmospheric pressure

• Vapor density: lighter than air (0.6 relative to air)

• Solubility: highly soluble in water

• Flammability range: 15-28% in air (narrow range)

• Auto-ignition temperature: 651°C (1204°F)

• Molecular weight: 17.03 g/mol

Ammonia Forms and Applications:

• Anhydrous ammonia: 99.5%+ pure, liquefied under pressure

• Aqueous ammonia: 5-30% solutions in water

• Industrial applications: fertilizers, refrigeration, chemicals

• Production processes: Haber-Bosch synthesis

• Global usage and economic importance

• Storage and transportation methods

Why Ammonia Is Hazardous:

• High toxicity and reactivity

• Corrosive to tissues

• Flammable and explosive potential

• Pressure hazards in storage systems

• Environmental impact of releases

Afternoon Session: Health Hazards and Exposure

Ammonia Health Effects

Understanding health risks and exposure limits:

Routes of Exposure:

• Inhalation: primary route of exposure

• Eye contact: severe damage risk

• Skin contact: chemical burns

• Ingestion: rare but extremely dangerous

Acute Health Effects:

• Irritation: eyes, nose, throat at low concentrations

• Respiratory effects: coughing, bronchospasm, pulmonary edema

• Eye damage: corneal burns, permanent vision loss

• Skin burns: chemical burns, blistering

• Systemic effects: shock, cardiovascular collapse

• Concentration-dependent severity

Exposure Limits:

• OSHA PEL: 50 ppm (8-hour TWA)

• NIOSH REL: 25 ppm (10-hour TWA)

• STEL (Short-Term Exposure Limit): 35 ppm

• IDLH (Immediately Dangerous to Life/Health): 300 ppm

• Odor threshold: 5-50 ppm (varies by individual)

• Lethal concentration: 5,000+ ppm for 30 minutes

Chronic Health Effects:

• Chronic bronchitis and asthma

• Permanent eye damage

• Skin sensitization

• Respiratory system damage

• Long-term exposure consequences

Vulnerable Populations:

• Pre-existing respiratory conditions

• Pregnant workers

• Workers with eye disorders

• Skin condition sensitivities

Day 2: Safe Work Practices and Procedures

Morning Session: Engineering and Administrative Controls

Controlling Ammonia Exposure

Implementing hierarchy of controls:

Engineering Controls:

• Closed-loop systems: primary containment

• Ventilation systems: local exhaust and general

• Gas detection and alarm systems

• Emergency shutdown systems

• Pressure relief devices

• Secondary containment and dikes

• Scrubber systems for emissions

Administrative Controls:

• Standard operating procedures (SOPs)

• Permit-to-work systems: hot work, confined space

• Lockout/tagout (LOTO) procedures

• Training and competency requirements

• Buddy system for high-risk activities

• Work schedules and exposure time limits

• Medical surveillance programs

Safe Work Practices:

• Pre-job safety briefings and JSAs

• Area inspection before work

• Proper tool and equipment selection

• Communication protocols

• Housekeeping and leak prevention

• Equipment inspection and maintenance

• Incident reporting procedures

Afternoon Session: Personal Protective Equipment

PPE Selection and Use

Mastering personal protective equipment:

Respiratory Protection:

• Air-purifying respirators: cartridge types and limitations

• Supplied-air respirators: airline systems

• Self-contained breathing apparatus (SCBA): emergency use

• Fit testing requirements and frequency

• Cartridge change-out schedules

• Proper donning and doffing procedures

• Limitations and breakthrough times

Eye and Face Protection:

• Chemical splash goggles

• Full-face shields for severe exposure risk

• Contact lens restrictions

• Anti-fog treatments and maintenance

• Emergency eyewash station locations

Skin Protection:

• Chemical-resistant gloves: neoprene, butyl rubber

• Chemical suits for major exposures

• Boots and footwear requirements

• Proper selection based on concentration

• Decontamination procedures

• PPE inspection and replacement

PPE Maintenance:

• Cleaning and storage procedures

• Inspection before each use

• Replacement criteria and schedules

• Documentation and record-keeping

Day 3: Ammonia Systems and Equipment

Morning Session: Storage and Handling Systems

Understanding Ammonia Equipment

Knowledge of ammonia systems:

Storage Systems:

• Refrigerated atmospheric storage: large-scale facilities

• Pressurized storage: bullets, spheres, cylinders

• Tank design: ASME codes and standards

• Capacity ranges and typical configurations

• Insulation and refrigeration systems

• Instrumentation: level, pressure, temperature

Piping and Transfer Systems:

• Piping materials: carbon steel, stainless steel

• Valve types: manual, automatic, emergency

• Transfer pumps and compressors

• Hoses and flexible connections

• Loading/unloading systems

• Vapor return lines and recovery

Safety Systems:

• Pressure relief valves (PRVs)

• Emergency isolation valves

• Gas detection systems: fixed and portable

• Water deluge and spray systems

• Emergency shutdown (ESD) systems

• Alarms and notification systems

Afternoon Session: Refrigeration Systems

Ammonia Refrigeration

Understanding ammonia refrigeration applications:

Refrigeration System Components:

• Compressors: reciprocating, screw, centrifugal

• Condensers and evaporators

• Receiver vessels and accumulators

• Expansion valves and controls

• Oil separators and purge systems

• Defrost systems and procedures

Operating Procedures:

• Normal startup and shutdown

• Capacity control and optimization

• Oil management and removal

• Defrost cycle operations

• Monitoring and trending parameters

• Abnormal condition recognition

IIAR Standards:

• IIAR 2: Equipment, Design, and Installation

• IIAR 3: Ammonia Refrigeration Valves

• IIAR 4: Installation of Closed-Circuit Ammonia Refrigeration Systems

• IIAR 6: Inspection, Testing, and Maintenance

• Compliance requirements and audits

Day 4: Emergency Response and Preparedness

Morning Session: Leak Detection and Response

Recognizing and Responding to Releases

Mastering emergency response:

Leak Detection Methods:

• Odor recognition (unreliable at high concentrations)

• Fixed gas detection systems: electrochemical, infrared

• Portable gas monitors and detectors

• Visual indicators: vapor clouds, ice formation

• Audible indicators: hissing, pressure release

• Monitoring system alarms

Emergency Response Priorities:

• Life safety first: evacuation and rescue

• Property protection secondary

• Environmental protection

• Incident command structure

• Communication and notifications

• Resource mobilization

Immediate Actions:

• Activate emergency alarm systems

• Evacuate affected areas immediately

• Account for personnel at muster points

• Call emergency services (911)

• Notify plant emergency response team

• Isolate leak source if safe to do so

• Activate water deluge systems

Personal Protective Actions:

• Move upwind, uphill, and upstream

• Seek shelter indoors with closed windows

• Shelter-in-place procedures

• Evacuation routes and assembly points

• Communication during emergencies

Afternoon Session: Emergency Procedures

Emergency Management

Implementing response procedures:

Spill and Leak Response:

• Small leak containment procedures

• Large release evacuation zones

• Water spray curtains for vapor suppression

• Dilution with water (if safe and appropriate)

• Isolation valve operation

• Remote shutdown procedures

Fire Response:

• Ammonia fire characteristics

• Appropriate extinguishing agents

• Let fire burn if stopping flow not possible

• Cool surrounding containers

• Withdraw if storage tanks involved

• Firefighting tactics and safety zones

First Aid and Medical Response:

• Remove victim from exposure immediately

• Fresh air and rest

• Eye irrigation: 15+ minutes with water

• Skin washing: remove contaminated clothing

• CPR if breathing stopped

• Seek immediate medical attention

• Never give anything by mouth to unconscious victim

Decontamination:

• Emergency shower and eyewash use

• Clothing removal and disposal

• Equipment decontamination

• Area cleanup and restoration

• Waste disposal requirements

Day 5: Regulatory Compliance and Practical Exercises

Morning Session: Regulations and Standards

Legal Requirements

Understanding regulatory compliance:

OSHA Requirements:

• 29 CFR 1910.111: Storage and Handling of Anhydrous Ammonia

• 29 CFR 1910.119: Process Safety Management (PSM)

• 29 CFR 1910.134: Respiratory Protection

• 29 CFR 1910.146: Permit-Required Confined Spaces

• 29 CFR 1910.1200: Hazard Communication

• Recordkeeping and documentation

EPA Requirements:

• Risk Management Program (RMP): 40 CFR Part 68

• Clean Air Act regulations

• Emergency Planning and Community Right-to-Know Act (EPCRA)

• Release reporting requirements (CERCLA)

• Tier II reporting

• Emergency action plans

DOT Regulations:

• Transportation of ammonia: 49 CFR

• Container specifications and placarding

• Driver training requirements

• Shipping papers and manifests

• Emergency response information

Industry Standards:

• ANSI/IIAR standards for ammonia refrigeration

• ASME codes for pressure vessels

• API standards (where applicable)

• NFPA 58: Liquefied Petroleum Gas Code

Afternoon Session: Practical Exercises

Hands-On Training

Applying knowledge through practice:

PPE Donning and Doffing:

• Proper respirator fit testing

• SCBA operation practice

• Chemical suit donning sequence

• Decontamination procedures

• Emergency equipment removal

Gas Detection Practice:

• Operating portable gas monitors

• Interpreting readings and alarms

• Calibration and bump testing

• Response to detection alarms

• Multi-gas meter operations

Emergency Scenarios:

• Simulated leak detection and response

• Evacuation drills and procedures

• First aid scenario practice

• Emergency communication exercises

• Tabletop emergency exercises

• Incident command practice

Equipment Demonstrations:

• Emergency shutdown system activation

• Valve isolation procedures

• Water deluge system operation

• Eyewash and safety shower use

• Fire extinguisher operation

Course Assessment:

• Written examination on ammonia awareness

• Practical skills evaluation

• Emergency scenario response test

• Certificate of completion issuance

Course Deliverables

Participants Receive:

• Comprehensive ammonia safety manual

• Quick reference cards for emergencies

• PPE selection guide

• Emergency response procedures

• Regulatory compliance checklist

• Certificate of completion (valid 3 years)

• Wallet card for ammonia awareness training

Interactive Components:

• Hands-on PPE practice

• Gas detection equipment operation

• Emergency drill participation

• Group scenario discussions

• Video demonstrations

Why This Training Is Critical

Key Benefits:

• Prevent ammonia-related injuries and fatalities

• Ensure regulatory compliance (OSHA, EPA)

• Reduce liability and insurance costs

• Improve emergency preparedness

• Build safety culture and awareness

• Protect community and environment

Legal Requirements:

• OSHA mandates training for ammonia workers

• PSM and RMP compliance requires documentation

• Annual refresher training recommended

• Site-specific training supplements