Awareness Training Goals - Salinas Valley Ammonia Safety Day

Ammonia Safety Day 

“We will not accept another operator injury or death due to exposure to ammonia; 

evidence shows that it is far too simple to avoid! Basic safety knowledge and personal 

protective equipment (PPE) WILL SAVE YOUR LIFE! Consider that all pipelines are 

pressurized and do not trust that a valve position is as you think it is – double check and 

treat routine circumstances with caution – trust but verify! Use lock-out-tag-out, process 

safety measures like cutting/welding permits, and wear your PPE!” 

“Most emergency events last for an average of 3 hours and require the evacuation of 

downwind populations since the smell of ammonia creates community unrest: this is 

unacceptable. A properly prepared operator can stop most ammonia incidents through 

preventative action. If a release occurs, the operator (with proper PPE) can take steps to 

stop the incident when it is small (incidental response mode). If the incident becomes an 

emergency event, the relationship with public safety and regulators becomes very 

critical. Unified command and appropriate incident action plans and safety plans should 

lead to safe and effective control of the emergency event.” 

Awareness Training Goals 

Use “Prevention, Mitigation, and Preparedness- P.M.P.” work safe and point out hazards 

and risks; be disciplined to work within the Standards of Operation; ask questions if you 

don’t know and learn the consequences of your actions; and when considering whether to 

operate an ammonia system valve, don’t go if you don’t know, let the professionals who 

know how to operate the system train you before working on a system. 

“Prevent them all or stop them small” and safely approach with proper PPE when 

performing service, maintenance, leak investigation, and response to emergency events; if 

you are not involved in the system repair, maintenance, service, or leak investigation then 

avoid the area, move to a safe location away from a potential release. 

Use the “One-Plan” to coordinate the emergency event effectively; learn how to effectively 

put L.A.N.C.E. into service; work in conjunction with the facility emergency response plan 

©ASTI – www.ammonia-safety.com – August 2008 1


Chemical Characteristics of NH3 

-Boiling at -28ºF; Freezing -108°F 

-Expansion rate = 840 to 1 

-Vapor absorption rate into water =1300 to 1 

-Vapor density = 0.6 (Air = 1.0) 

-Alkaline = pH of 11.6 

-Flammability = 1204 ºF ignition temperature, 

850 ºF disassociation, 16% to 25% mix with 

air, widens with compressor oil and humidity 

-Reacts dangerously with chlorine, oxidizers, 

and acids (see MSDS for details) 

-Avoid copper, brass, silver, zinc or their alloys 

Physical Characteristics 

-Cone-shaped cloud with a v-pattern; rises and 

falls depending on humidity and climatic 

pressure inversions 

-Aerosol Dense Gas/Stream, Vapor, or Liquid 

-Loves water, moisture, vegetation, cool places; 

will move cross-wind to get to water 

-Warm air moves to cooler NH3 gas clouds 

-Aerosol releases are extremely cold and may 

reach -80ºF to -100ºF; NH3 freezes at -108ºF 

Health - “Rule of 5’s” 

5 – 20 PPM = Detectible by smell 

25 PPM = California/Washington PEL 

35 PPM = STEL for 15 minutes 

50 PPM = OSHA Permissible Exposure Limit 

300 PPM = IDLH – Must wear a SCBA 

1,500 to 1,700 PPM = Coughing and choking 

5,000 PPM = Extremely dangerous/deadly 

15,000 to 30,000 PPM = Skin burning/blisters 

Threats 

-Overpressure: Caution for NH3 liquid being 

trapped between valves; ammonia builds 

pressure when heated (check your condenser) 

-Release: Extreme caution for aerosol stream 

and dense gas; sub-cooled liquid may flash 

and spit when exposed to ambient conditions 

-Fire: Ammonia gas will ignite when trapped in 

a room or area at 16% to 25%; high risk 

concern begins at 15,000 PPM (ventilate and 

control sources of ignition before entering) 

2 

“The Entire Picture” 

Make the Connections Among: 

• Chemical/Physical 

• Health Effects 

• Potential Scenarios 

• Hazards and Threats 

• Prevention, Mitigation, Preparedness 

• Emergency Response and EMS 

Emergency Scenario Situations 

-Aerosol release in close proximity to community 

-Release while working near the system doing 

maintenance, service, and while investigating a leak 

or filling the system – Wear your PPE! 

-Contained dense gas in a room with source of ignition 

-Vapor release affecting evacuation 

-Trapping liquid ammonia or allowing a slug of liquid 

ammonia to enter the compressor 

-Theft, terrorism, natural disaster 

Service, Incidental, and Emergency Events 

-Maintenance release – Wear PPE and follow SOP 

-Incidental release – Escape when risk threatens 

workers or others exposed people; wear PPE 

-Emergency event – Discovery, Initial Response, 

Sustained Response, Termination 

Prevention and Mitigation 

-Inspection, maintenance, and housekeeping 

-Ventilation and pressure management 

-Containment and Control systems 

-Crash mitigation 

-Monitoring system for leaks/pressure 

-Valve and pipeline inspection 

-Replace threaded short nipples 

-Manage ice build up 

-Calibrate ammonia monitors 

Preparedness – Readiness and Discipline 

-SOPs for operations and leak control 

-Warning signs, valve tags, pipeline labels 

-P&ID charts, site and building plans 

-Service and maintenance training 

-Responder equipment and PPE readiness 

-Public safety training and preparedness 

-Emergency Response Plan strategy in sync 

with PPE and training readiness 

-Open valves slowly, consider every pipeline to 

be pressurized, review SOP and valve 

position; “If you don’t KNOW don’t GO!” 

Response 

-Establish incidental response protocols 

-Train on LANCE and SIMPLE 

-Downwind and community SIP/Evacuation 

-Check the P&IDs and Leak Control SOPs 

-Check the facility ERP or EAP 

Emergency Medical Concerns 

Managing Risks and Hazards 

-Vapor exposure: Causes discomfort (tears, 

-Ammonia may cause olfactory fatigue at low levels 

coughing, mucous) that clears up with fresh 

-Crash may cause damaged vessel, pipeline, or valve 

air or transitions to pain when breathing; lung 

(reduce pressure, isolate and contain NH3) 

sounds should be checked out by a doctor 

-Broken line or fitting or leaking valve (isolate, control -Aerosol or Liquid: Burns require 15 to 30 

pressure and re-direct liquid flow) – consider all 

minutes of water flushing; frozen clothing 

pipelines pressurized and be aware of sub-cooled 

must be thawed before removal 

liquid ready to spit out when exposed to ambient air 

-Eye exposure: 15 to 30 min. of water flushing 

-Over-filled vessel or cylinder (reduce pressure and 

-Heart Attack: CPR beginning with 300 

bleed off the vapor – requires 20% vapor space) 

compressions and immediately call 9-1-1 

-Overpressure from heated or over-filled vessel or 

-Heat-related injury: Cool the victim, treat for 

cylinder (reduce pressure and re-direct liquid flow) 

shock, check vitals, and call 9-1-1 

-Slugging or trapping (operate within technical 

-Emergency medical information available by 

specifications) 

calling CHEMTREC at 800-262-8200 

©ASTI – www.ammonia-safety.com – August 2008

Lowest Common Denominators 

For Safety and Readiness 

“Prevent them all or Stop them Small!” 

PMP 

Prreeveentt 

Mi itti igattee 

Prreeparree 

“Wal lk tthee 

Tal lk” 

Plan for On-Site 

and Off-Site 

Readiness; 

Evaluate and 

Continuously 

Improve! 

Identify Risks and 

Manage Hazards 

Cycle of Safety 

and One-Plan 

Emergency 

Readiness 

Response and 

Recovery 

LANCE 

SIMPLE 

The One Pllan 

Emergency 

Response 

PPE & SOP 

Peerrssonal l 

Prrotteecctti ivee 

Equi ipmeentt 

Establish 

Strategy, 

Train, and 

Build the 

Defensive and 

Offensive 

SOPs 

“Strengthen the ‘Cyclle of Safety’ and buiilld a 

stronger safety cullture connectiion between 

emplloyees,, publliic safety and the communiity!” 




4 

Workbook Questions - Ask SAL Monia – Chemical and Physical Traits 

Meet SAL Monia – Some Friendly and Live Saving Advice 

SAL Monia – Self Alarming 

Liquid - The Ammonia Genie 

SAL sleeps in his bottle (vessel) 

when under low pressure & 

temperature and as a liquid, 

SAL spits as an aerosol with a 

freezing sting 

SAL is cool and loves water and 

may form a dense gas 

SAL half as heavy as air except 

when he mixes with water vapor 

SAL travels in predictable ways 

move lateral and upwind or SIP to 

avoid him 

SAL if he gets on you wash him off 

30 minutes be aware of frozen 

clothing – wear safety gear! 

1. What is the significance of SAL’s name? 

2. What are his “two very different sides”? 

3. Why is SAL a “challenging character” to humans; a real “stinker”? 

4. What is SAL’s warning to those of you who work on ammonia systems? What’s he say about you 

“messing with the system”? 

5. SAL mentions that when operators don’t respect him and work on his system without PPE or proper 

SOP he “spits out an aerosol spray with a freeze burn” – What’s the lesson in that statement? 

Chemical and Physical Characteristics Get to know SAL 

Four Phases of Ammonia 

Aerosol and Dense Gas 

Vapor and Liquid 

Aerosol, Dense Gas, & Vapor 

High Pressure Aerosol 

Low Pressure Aerosol 



6. Why is SAL “so darn thirsty”? Where does he find water? What forms when he mixes with water? 

7. What are the four types of ammonia releases that emergency responders should be aware of? 

8. What happens to SAL’s pressure as he heats up and cools down? 

9. Why is SAL considered as a great refrigerant? 

10. At what temperature does SAL sleep? Can he get colder than his boiling point? Why? 

11. When SAL escapes his vessel what powers does he have to be very dangerous? 

12. How do we contain SAL in a building or when leaking from a vessel? 

13. What happens when SAL’s vapor moves downwind and hits the buildings in the downwind or mixes 

with humidity and vegetation? 

14. Identify three ways you would escape from SAL’s vapors: 

15. Why does SAL need a vapor space when contained in a pipe or vessel? What’s it mean when SAL 

“pops the cork so to speak”? 

16. What is the significance of the term olfactory fatigue? 

17. What are the key concerns about proper shelter in place tactics? 

18. What is SAL’s warning about an aerosol burn? How long should you flush with water? Should you 

rub the burn area? Why are your eyes so vulnerable to injury by SAL? 

6 

Ammonia Contained 

KING VALVE 

OUT SIDE SPACE 

Head Pressure 

(Ambient) 

(High Side) 

RECEIVER 5 

MECHANICAL ROOM 

(ENGINE-ROOM) 

LP LIQ 

HP LIQ 

soleniod valve 

7 

HP LIQ 

FLASH 

COOLER 

LP LIQ /VAP 

EXPANSION 

VALVE 

3 

Heat Load - Out 

B.T.U's 

CONDENSER 

LOW PRESSURE RECEIVER 

9 

AMMONIA PUMP 

Heat Load - In 

B.T.U's 

EVAPORATOR 

CONDITIONED SPACE 

(WAREHOUSE FREEZER OR COOLER) 

LP VAP /LIQ 

COMPONENTS HIGH SIDE / LOW SIDE SEPARATION AMMONIA STATE SUB-SPLITS INTERCOOLER VESSEL AMMONIA PUMP 

FLOW KING VALVE HEAT GAINS STATE CHANGES LOW PRESSURE VESSEL SHUT-OFF VALVES 

HIGH PRESSURE RECEIVER HEAT REMOVAL SOLENIOD VALVES 

PRESSURES / TEMPERATURES 

8 

2 

4 

©ASTI – www.ammonia-safety.com – August 2008 5 

HP VAP 

LP VAP 

HP VAP 

COMPRESSOR 

1 

LP VAP 

INTERMEDIATE PRESSURE 

(Low Side) 

MAIN 

COMPRESSOR 

SUCTION 

SIDE 

PORT 

SUCTION 

S-6


6 

Flammability 

19. What is SAL’s warning when large amounts of his vapor enter a confined room with no ventilation? 

What is needed for SAL to ignite into a powerful ball of flame? 

20. Why is SAL more sensitive when water is dumped on him rather than for him to jump into the water? 

LANCE – The super hero! 

Readiness for a Release 

21. What does L.A.N.C.E. stand for? 

43 

Respiratory 

System 

Upper Respiratory: 

large particulate 

capture, water 

soluble gases 

Lower Respiratory: 

5 μ particles, low 

solubility gases 

Mucocilary 

escalator 

removes 

contaminants 

LANCE Implemented: LANCE is an acronym designed to help focus on priority concerns when 

assessing a potential ammonia emergency event. LANCE should take less than a minute to mentally 

review. The LANCE protocol should be continually evaluated for as long as the incident is “out of 

control.” LANCE stands for: 

Life safety first 



Initiate emergency action plan. Set the hot zone and define the area most at risk for the first stage of your 

response; help people escape - rescue (when properly trained and PPE equipped). If the leak is incidental, 

stop the leak by following equipment shutdown procedures if it’s possible to do so without being exposed 

to ammonia above the permissible exposure limit or IDLH when wearing proper PPE. 

Alert facility response team 

Contact the Facility Emergency Coordinator and on-site response team. When the personnel arrive, inform 

them of the site status, employee location, medical emergencies and severity of the incident. The Facility 

Emergency Coordinator (FEC) should take command and implement LANCE and SIMPLE protocols. All 

members of the response team must be properly trained and equipped with PPE. 

Notify 

Call 911 for local emergency response support; call them early to stop the problem when it is small. Also 

report to local, state, and national response officials immediately (within 15 minutes) if containment of the 

release is not achieved and the release is perceived to have reached the reportable quantity, or if exposure 

to offsite receptors is likely or has occurred. The Facility Emergency coordinator may request trained 

office staff to make the actual calls using the “One Plan” forms. Reporting requirements for local and state 

regulatory agencies must be incorporated into the response plan. 

Contain and Control 

Restrict the release by closing doors. Consider closing the king valve or the main liquid and hot gas 

supply valve to stop the flow of ammonia to the affected equipment if applicable to the situation. These 

valves are defined in the P&IDs, valve tags, pipeline labels, and leak control SOP’s with digital 

photographs. In some instances the trained operator may elect to operate certain equipment in order to 

help minimize the release in affected areas. 

Evacuate 

Move laterally and upwind. Some instances may be suited for sheltering in place. Move all personnel not 

involved in refrigeration control activities to a safe distance from the affected area. Assess the extent of a 

release area with monitoring equipment and include the property perimeter to determine whether any 

neighboring off-site receptors are affected and notification must be issued. Refer to the building and site 

plans and map out the evacuation strategy. The FEC should consider appointing an Evacuation 

Coordinator and use Public Address System communications to alert facility employees to the direction of 

the ammonia release and any specific evacuation considerations. 

Transition to SIMPLE Plan: When LANCE is completed, take a breath, gather your composure and 

consider the containment and control plan by reviewing the SIMPLE plan. 

Injury Prevention & Health Concerns 

22. Give an example of Prevention, Mitigation, and Preparation? 

23. What type of personal protective equipment (PPE) should an operator wear when working around the 

ammonia system? 

24. What’s the immediate area of concern should a problem develop while working on the system? 



25. What is the lowest level that most people can smell ammonia? What is the PEL for SAL? _______ 

PPM and what does that mean? What is the IDLH: ______ PPM and what does that mean? 

Evacuation and Emergency Medical 

8 

No Tolerance for Injury – 

Escape and Safe Location is 

VERY Doable! 

Escape: Lateral, upwind, or shelter 

in place; go for the person with the 

PPE 

Decide: Time to evacuate or need to 

Shelter in Place? 

Evacuation: Must be coordinated 

and communicated – everyone 

must participate! 

Shelter in Place: Works especially 

well for ammonia – SAL seeks the 

cool and moves with the wind; just 

shut down HVAC and tune into the 

emergency broadcast radio station 

for instructions. 

26. Identify three concerns you would have if you were approaching an ammonia cloud? 

27. Identify three choices you have when escaping an ammonia release: 

28. Identify three different emergency response leaders you would attempt to contact should you be 

trapped inside and unable to escape an ammonia release? 

29. How would you communicate with the Facility Emergency Coordinator or the public safety Incident 

Commander if you did not have a radio? 

30. What are four things you can do to protect yourself during an ammonia release that is threatening your 

shelter in place location? 

31. You are doing maintenance and smell an odor of ammonia, you check it out and see that it is a leaking 

valve packing. What protocol would you use? 

32. How does your body react when it takes in a lot of ammonia vapor? At what point does the level of 

ammonia cause your breathing to stop? 

33. Identify four steps to helping a person who has just met you after escaping through an aerosol 

ammonia release? What would you do if the person swallowed some ammonia liquid? 


The SIMPLE Plan 

Take a breath and think SIMPLE 

Sources of ignition: Confined gas 

cloud? Electrical, gas fired 

appliances? 

Isolation: King valve, isolate 

upstream and downstream without 

trapping liquid 

Manage Pressure: High side – shut 

down compressors; Low side 

transfer pressure and reduce 

overall pressures 

Positive Pressure Ventilation: Plan 

for the spread of vapor downwind 

LANCE: Do it again! 

Emergency Response Plan: The 30 

Minute Plan 


34. What’s LANCE’s recommendation about ammonia and its mixture with chlorine? What’s the threat of 

ammonia soaking into the ground? 

Sources of ignition 

Evaluate explosion (flash fire – deflagration hazard) potential in enclosed rooms and confined spaces with 

monitoring equipment as needed. Ammonia can ignite when in its explosive range of 16% to 25% 

concentration or less in air when other flammables are present with an ignition source. Disconnecting 

electrical service to the facility may be required which may affect the operation of ventilation equipment. 

Assure that ventilation equipment is properly wired for operations in high ammonia concentrations: 

separate circuitry and electrical code requirements for Class and Division wiring techniques vary from 

local and state mandates. Relocate employees and response personnel to a safe distance when necessary. 

Isolate the release 

Manage the liquid source by turning off the supply (King Valve) or upstream and downstream valves 

without trapping liquid. The P&IDs, digital photographs, and leak control SOPs should indicate all key 

valves and containment options. 

Manage the Pressure 

Reduce system pressure to reduce system flow. If the leak is on the high side, stop the compressors. If the 

leak is on the low side, transfer of pressure or re-direction of the liquid flow and the temperature demand 

may be required to reduce flow by operating equipment. Consult your PSM protocols and SOPs for 

system controls. 

Positive pressure ventilation 

Reduce exposure potential whenever possible to lowest levels possible. Be aware of downwind receptors 

and air movement within the facility. 


44


LANCE again 

Do it again! LANCE and immediately notify local, state and federal authorities. Make sure that local, 

state, and the National Response Center notifications are completed within 15 minutes of the FEC 

recognizing the emergency incident – assign trained security or administrative personnel to do the calling. 

Emergency Response Plan 

Follow the facility response procedures of the 30-Minute Plan structure, written Incident Action Plan, and 

Safety Plan. First Responders meet in one location to coordinate information and resources with the 

Incident Commander. Develop a written safety plan and incident action plan before proceeding with 

offensive tactics and strategy. Prepare the entry TEAM with back-up responders and communications 

when deemed necessary. Repairs involving Hazmat response activity are permitted only when conducted 

within the incident command structure of Public Safety officials with jurisdiction. 

10 

Preparing for and Preventing Ammonia Releases 

1. How ammonia is released: 

• Opening the system: 

o Maintenance 

o Construction 

• Accidents: 

o Piping or equipment hit 

o Fire 

o Natural disasters 

• Equipment failure: 

o Solenoid: wire drawn, plug stuck, etc. 

o Pressure regulator: diaphragm failure, piston stuck 

o Compressor: internal part wearing 

o Seal failure 

o Corrosion 

• No operating procedure or not following procedures 

• Lack of or inadequate training for a task 

• Theft 

2. Preparedness and prevention of releases: 

• Education and Training: 

o IIAR (Video and DVD) 

Basic Ammonia Refrigeration (6 modules): Introduction to Ammonia Refrigeration; 

Ammonia Refrigeration Systems; Evaporators; Compressors; Condensers; Shut-off 

Valves 

Ammonia Safety (4 modules): Introduction to Personal Protective Equipment; Use of 

Personal Protective Equipment; Emergency Response; Ammonia Safety: Emergency 

Response Procedures 

Removing oil from an ammonia refrigeration system 

o IIAR Technical Papers 

o IIAR Condenser 

o RETA Course Books 

Refrigeration Series 



Electricity Series 

Control Theory, Schematics and Troubleshooting 

Energy Conservation 

Safety and Regulatory 

Practical Problems in Mathematics for Heating and Cooling Technicians 

o RETA “The Technical Report” 

o RETA Breeze 

o RETA Convention Chronicle 

o IIAR and RETA annual conventions 

• IIAR Bulletins and Guidelines: 

o Ammonia Refrigeration Training Guideline 

o Bulletin 107 – Guidelines for: Suggested Safety and Operating Procedures when Making 

Refrigeration Plant Tie-Ins 

o Bulletin 108 – Guidelines for: Water Contamination in Ammonia Refrigeration Systems 

o Bulletin 109 – Guidelines for: IIAR Minimum Safety Criteria for a Safe Ammonia 

Refrigeration System 

o Bulletin 110 – Guidelines for: Start-up, Inspection and Maintenance of Ammonia 

Mechanical Refrigeration Systems 

o Bulletin 111 – Guidelines for: Ammonia Machinery Room Ventilation 

o Bulletin 112 – Guidelines for: Ammonia Machine Room Design 

o Bulletin 114 – Guidelines for: Identification of Ammonia Refrigeration System Piping and 

System Components 

o Bulletin 116 – Avoiding Component Failure in Industrial Refrigeration Systems Caused by 

Abnormal Pressure or Shock 

• Standards: 

o American National Standard: Safety Code for Mechanical Refrigeration - ANSI/ASHRAE 

Standard 15 - 2007 

o American National Standard for Equipment, Design and Installation of Ammonia 

Mechanical Refrigerating Systems - ANSI/IIAR Standard 2 -1999 

o Ammonia Refrigeration Valves - ANSI/IIAR Standard 3 – 2005 

• Regulatory Guidelines (IIAR): 

o Risk Management Program Guidelines For Ammonia Refrigeration 

o Process Safety Management Guidelines For Ammonia Refrigeration 

o Ammonia Refrigeration Management (facilities with less than 10,000 lbs.) 

• Continuing Education: 

o Hazmat Courses: Operations, Technician, Incident Commander 

o Refrigeration Training courses from technical colleges 

o Seminars 

o Ammonia equipment supplier presentations 

o In-house 

Incident Action Planning Using LANCE and SIMPLE Procedures 

The Emergency Action or Emergency Response Plan and Fire Prevention plans include procedures for 

incidental ammonia release, fire or other emergencies. The Plan provides information necessary to protect 

employees from various hazards during emergency situations by relocating individuals away from the 

affected area to a Designated Meeting Location or by Sheltering in Place. 



First Responder Awareness training is provided to employees who are assigned duties by the Facility 

Emergency Coordinators (FEC). 

Pre-Incident: These are critical first steps to operations BEFORE considering any move to control an 

emergency event: 

• Response plan agreement between all of the responders and response agencies (public safety and 

local regulator) 

• PPE readiness and safety – PROTECT your team members by having them wear proper PPE 

before the system is opened or manipulated 

• Valve and pipeline readiness concerns: 

o Consider all lines to be pressurized – never open a system and think it’s completely void of 

ammonia – special caution for the sub-cooled liquid 

o Double check valves before you open the system, downstream and upstream 

o When you work on a system and you aren’t sure of the consequences of your actions 

DON’T do it. Check the protocols and SOPs and work with a supervisor or a systems 

engineer to understand the consequences of a possible failure in the system! 

General: Upon discovery of an incident, it’s important for the First Responder to size up an emergency 

situation and identify what happened. Are lives and the environment at risk? What stage of the event is 

happening now? What needs to be done next? Answer these key questions in order to prioritize which 

actions to take and determine what the initial response will be. 

Employees will be required to take the following action in the event of an emergency due to an 

unintentional ammonia release, fire or other emergency: 

1. Upon notification, employees and visitors immediately follow the procedures described in the 

Emergency Action and Fire Prevention plans for evacuation. They will either assemble at a designated 

meeting location or shelter in place, and will be accounted for by the emergency coordinator. 

2. The engineering manager, the refrigeration operators, or refrigeration contractor, are permitted to take 

defensive action to control the leak to the extent of their training but will take no aggressive action that 

would require entry into an area containing ammonia concentrations above the permissible exposure 

limits without first donning the appropriate level of respiratory protection and personal protective 

equipment. 

On Site Readiness: Facility Emergency Coordinator (FEC): The person in charge of any emergency 

incident must be designated and trained to fill that position. At least 2 people for each working shift 

should be trained at that level. Training will be in accordance with the following: 

Level 1: Defense only, under 300 PPM, supported by local public safety trained to a pre-described level of 

readiness: a minimum of 8 hours of Operational training annually refreshed (8 hours) is recommended for 

response team members. FECs shall be trained to Technician level with special training on how to engage 

and utilize the Incident Command System. 

Level 2: Offense to 5,000 PPM with continuous monitoring while inside the hot zone. SCBA and 

chemical resistant suits recommended to have at least 60 minutes impermeability for ammonia, with the 

best being 480 minutes; Technician trained with 24 hours of training supported by 8 hours of refresher 

mandated; skill tested with Level B equipment at least 3 times per year for each response team member; 

12 



FECs shall be trained to Technician level with special training on how to engage and utilize the Incident 

Command System, with emphasis on how to operate in a Unified Command. 

Level 3: Offense with the highest level of PPE supported by the fire department hazmat team. Situations 

in which flammability is a concern should be avoided (ammonia escaping into an enclosed room that is 

not effectively ventilating gases to the outside). The flammable limits are generally 16% to 25% 

(compressor oil and other contaminants may change the limits). ASTI recommends extreme caution at 

15,000 PPM and extreme concern at 40,000 PPM, as the speed of concentration of an “out of control” 

ammonia release in an enclosed room can reach flammable limits within a few minutes. The Level A 

responder must also be aware of the low temperature hazards and risk when working around liquid stream 

aerosols and dense gas cloud releases. Technician trained 24 hours of training supported by 8 hours of 

refresher mandated; skill tested with Level A PPE at least 4 times per year (ASTI recommendation) for 

each member of the response team; FECs shall be trained to Technician level with special training on how 

to engage and utilize the Incident Command System and participating in a Unified Command operation. 

Note: Trained employee responders should take no offensive response without the support of local 

emergency authorities. All response activities must occur within the incident command structure and be 

coordinated with public safety officials in charge of emergency response scene management. 

Practices for First Responders when dealing with emergency situations: 

ASTI recommends that the Facility Emergency Coordinator request to work under a “Unified 

Command” structure with Public Safety Officials. This is the accepted method and approach for private 

industry to assist with mitigation during an emergency response. Offensive action to control a release 

should be coordinated with public safety officials using “One Plan” logic and conducted within “Incident 

Command System” scene management. Only employees who meet the qualifications required by OSHA 

29 CFR 1910.120 may be certified by the employer to participate in response to emergency events 

involving ammonia. HAZWOPER regulations must be applied to handling hazardous waste and 

hazardous materials other than the ammonia emergency response. 

Hazard and Risk in Focus – I.T.C. “In-Total-Control” 

Treatment of the injury is more costly than Preventing the problem! Don’t waste your PMP dollars. 

Spend them with a focus on high risk/high frequency challenges! 

Risks + Hazards + Frequency of Risks and Hazards = Level of Concern 

Level of Concern + PMPs + Safety Discipline = Acceptable Level of Risk 

Acceptable Level of Risk + Emergency Response Readiness = Managed Risk 

Three Golden Rules of Safe and Effective Hazard Control 

1. WEAR your PPE! Ammonia is dangerous, but it’s easy to protect yourself. At a minimum, wear 

respiratory and face protection, helmet, gloves, full skin coverage at ANY time you are going to open 

or manipulate the system in a fashion that could allow SAL Monia to escape! 

2. If you don’t know, don’t go! ALWAYS know the consequences (domino effect) of your actions 

while working on a system. Review the P&IDs and the SOPs. If you are unsure, or don’t know, ASK 

your supervisor, and remember that the installation engineer, installation contractor, and/or the 

equipment vendors are great sources of informational support. 

3. ALWAYS consider pipelines pressurized, double check the position of the upstream and 

downstream valves, and open valves slowly before commencing service, maintenance, or repair 

operations. 



Preparation for Maintenance, Repair, Service, Leak Investigation 

“All pipelines should be considered pressurized and the status of the valves CANNOT be trusted – 

double check and treat circumstances for the risk they present rather than to trust that things are what 

they seem to be! Wear PPE and follow SOP! This procedure provides guidance on how to approach 

maintenance, service, and leak investigation, and how to survive an incidental release and transition, if 

necessary, to emergency response mode. 

Facility Emergency Coordinator/Technician Operator Preparation Discussion: 

Review and test the method of contacting the on-site emergency response team; learn how to quickly 

and effectively engage the on-site response team 

Review the LANCE and SIMPLE procedures – use them to size up the situation and mentally prepare 

for developing the actual response plan. 

Make sure the facility Emergency Action Plan, leak control SOPs, P&IDs, and other plans that support 

emergency operations are available in an emergency. 

Take a digital picture of service, maintenance, or repair locations for future reference in an emergency. 

This also serves as a good record of repair. 

Fill out the “Worksheet: Service, Maintenance, Investigate, Repair, Incidental and Emergency Event 

Response Readiness” or other forms used to record service, maintenance, or repairs. 

Determining if the event is an “Incidental” or an “Emergency” event: Criteria for determining when 

the “incidental” release becomes an emergency event: 

1. A response is required from outside the immediate release area by an emergency response 

team; danger is imminent and an emergency exit is not readily available 

2. The incident requires evacuation of employees in the area 

3. The incident poses, or has potential to pose, conditions that are immediately dangerous to 

life and health (IDLH); more than 300 PPM of ammonia in the exit pathway 

4. The incident poses a serious threat of fire or explosion (a fire starts or overpressure exceeds 

safety mitigations) 

5. The incident requires immediate emergency response because of imminent danger (control 

or containment is unclear and building is in danger or at risk) 

6. The incident may cause high levels of exposure to toxic substances 

7. It is uncertain whether the employee in the work area can handle the severity of the hazard 

with the PPE and equipment that has been provided and the exposure limit could easily be 

exceeded 

8. The situation is unclear, or data is lacking on important factors 

Readiness for Fire, Overpressure and Release: 

Fire Readiness: Check location, service, and readiness of the fire extinguisher(s): travel distance 

within 75 feet of the work area and always immediately available when doing cutting and welding. 

Identify fire doors, fire walls, primary and secondary exits, and the fire safety readiness of the area to 

be worked on. Use cutting and welding permits, lock out/tag out, and any other process safeguards as 

established by facility safety SOPs. 

14 

Review SOP(s) for: Leak control, shut down/start up of compressors, King Valve operation, 

emergency ventilation, pressure management, and control/containment for overpressure, fire, or 

release 

Identify the location and operation of system components prior to operation, service or repair, or 

leak investigation; 


Piping and Instrumentation Diagram (P&ID), site plan, building plan, drainage plan 

Review the location and operation of key shut-off valves 

Do not trap liquid ammonia between closed valves with no relief valve protection 


Emergency Control System Location: Review the location and operation of each; provide digital 

pictures of the locations: 

Compressors Emergency Controls 

Low Side Pressure Management and Monitoring 

Ventilation Emergency Controls 

Electrical Power Control Panels 

King Valve Location/Operation 

Downwind Concerns (Site Plan) 

Downstream – Sewer/Storm Drainage and Floor Drain Stop Points 

ALWAYS lock out/tag out when working on the system 

Safety and Personal Protective Equipment Readiness: Location(s) for First Aid and 

Decontamination: 

First Aid: _____________________________________________________________________ 

Eye Wash: ____________________________________________________________________ 

Emergency Shower: ____________________________________________________________ 

Emergency Response Equipment: ________________________________________________ 

Personal Protective Equipment: Ammonia Safety Protective Equipment (ASPE gear) should be worn 

within 20 feet of a repair and at any time during repair, maintenance, service, or leak investigation and 

when working on the system in elevated locations. The maintenance engineer or system operators must be 

ready to act should an incident occur, and follow a daily check-out: 

Check operation of ammonia monitor 

Check operation of radio 

Check operation of flashlight 

Check condition and readiness of respirator (APR or SCBA) 

Check inventory: Ammonia Monitor (300 PPM), Emergency Response Cards (and emergency 

preparedness documents), inner and outer gloves, master key access/egress and control box, 

helmet, goggles, hearing protection, respirator mask, overalls (covering all skin) and safety boots 

PREVENTION of Fire, Overpressure and Release 

Access: Unobstructed access to exits, emergency controls, and emergency equipment 

Safe Storage: Hazardous materials, housekeeping, and stable storage structure so that access and 

movement of product is safe; pipe guards and clearance for access; clearance of combustibles from heat 

producing equipment 

Valve Operation: Key valves operate effectively (serviced and exercised regularly) and relief valves 

serviced and ready for operation (five-year change out) 

System Integrity: Corrosion control, repair all leaks, regular inspection and upgrade; eliminate threaded 

pipe connection, especially short nipples 

MITIGATION of Fire, Overpressure and Release 



System Monitoring: Calibrated and monitored for overpressure, release, and system operations 

High and Low Side: Identify key control valves and operational methods for manipulating the flow of 

ammonia to and from key components of the system (condensers, compressors, receivers, evaporators); 

methods of mitigating a release from oil pot and defrost problems; methods of managing pressure on the 

high, intermediate, and low side of the system 

Alert System: Method of issuing an incident alert and a communications system for employee/visitor 

movement; radio controlled communications on the PA system 

Fire Control Systems: Fire sprinkler system, fire extinguishers, water supply, fire access 

PREPARATION for Fire, Overpressure and Release 

PPE: For Facility Emergency Coordinator and on-site response team; those needed to implement LANCE 

and SIMPLE – minimum of two sets, one for Facility Emergency Coordinator and another for Operations 

trained person who can perform LANCE and SIMPLE 

Leak Control SOPs: Developed for each section of the ammonia system; high and low sides of the 

engine room; key control valves to isolate and contain releases to all components within the system. Leak 

control SOPs include a definition of the P&ID location of the isolation valves with due consideration of 

trapping ammonia – the strategy will be to control the amount of ammonia flowing to the problem 

location and to reduce system pressures in the location of the problem. 

Communications: Between Facility Emergency Coordinator and Technician- or Operations-trained 

personnel, and with those in charge of notification and evacuation; provide adequate access to phones and 

alerting systems 

SOPs and Plans: Evacuation, Emergency Notification, Maintenance, Incidental, Emergency Response, 

Restart, and Termination/Debriefing; also P&ID, Site and Building Plans. We recommend copies of the 

Emergency Response Cards for all key responders. 

Methods of Alert: Giving notice of an incident; communicating to those on site (audio alert and voice 

communications). We recommend setting up the radios used by command and control leaders to broadcast 

on the facility public address system to alert employees of special hazard circumstances. 

Emergency Response Equipment: PPE for responders and their back-up teams; one (preferably two) gas 

powered fan for emergency ventilation and decontamination; zone and control markers (placards, tape and 

cones to mark hot, warm and cold zones); decontamination equipment (fan, hose, water, catch basins, 

extra overalls); downwind/downstream, ammonia monitor to the limits of PPE, wind speed and direction 

indicators, valve control wrenches (placed strategically in multiple locations), and pH monitor. 

Emergency Medical Readiness: Water is your best friend when dealing with ammonia contamination. 

Flush with water, but do not rub. Continue for 15 to 30 minutes to draw ammonia out of the skin tissue. 

Also, be prepared to treat heat-related stresses: an emergency responder is subject to stress and high body 

heat, especially while wearing PPE. In some cases, the body will go into shock and a cardiac event may be 

triggered: be prepared to perform CPR. People exposed to higher doses of ammonia may experience 

nausea. 

Nausea is caused by a number of factors, the most common being the shock syndrome. Someone 

overcome with toxic fumes suffers system (body) compromise, setting up classic shock symptoms of 

weakness, shortness of breath, and nausea. Nausea may also result from swallowing minute amounts of 

ammonia which, when bound to saliva or fluid that is then mixed with gastric acid, causes a 

retching/nausea reaction. Inhalation of any toxic gas or offensive odor affects not only the olfactory 

system, but causes gagging and retching, a natural protective reaction of the body. This is similar to the 

nausea suffered by firefighters who choke and cough when overcome by smoke. 

16 



Worksheet: Service, Maintenance, Investigate, Repair, Incidental and 

Emergency Event Response Readiness 

Name(s) Technician: ____________________________________________________________________ 

Facility Emergency Coordinator: _________________________________________________________ 

Radio: _____________________ Cell Phone: ___________________ Phone: _____________________ 

Describe the operation to be performed and take a digital picture of the repair site: 

______________________________________________________________________________________ 

Entry Date/Time: _______________ Check-In Time(s): _______________________________________ 

Termination of Incident Time/Date:____________________ Details:_____________________________ 

_______________________________________________________________________________________ 

Emergency Entry PPE Readiness: 

Entry and Back-Up are trained and certified to act in accordance with the ERP 

Ammonia Safety Protective Gear - Communications, NH3 monitor, respirator, gloves, overalls, boots, 

goggles, Emergency Response Cards, etc. 

Emergency response equipment to include ventilation fans – serviced and ready to operate 

P&ID, leak SOPs, building, and site plans available 

LANCE Preparation: 

Life safety: Set the Hot Zone and evacuate non-essential personnel; check your PPE. 

Names of those working in the hot zone: _________________________________________________ 

Set perimeters and post placards: ______________________________________________________ 

Alert: Radio contact to the Facility Emergency Coordinator who will coordinate emergency response. 

Radio and/or phone contact for Facility Emergency Coordinator:____________________________ 

Who are the response team members available? ___________________________________________ 

Notification: Contact 9-1-1 for any probable emergency event. 

Give a LANCE and SIMPLE size up to Facility Emergency Coordinator and Emergency 

Responders 

Contain/Incidental Control: Close the doors and contain the release; control the leak source. 

Location of exit and entry doors:_________________________________________________________ 

Other Containment and Control Measures:________________________________________________ 

Evacuate or Shelter in Place: Evacuate upwind; S.I.P. if caught in the downwind. 

Describe the downwind: ________________________________________________________________ 

Describe the downwind SIP locations:____________________________________________________ 

Evacuation Coordinator: ______________________________________________________________ 

After completing LANCE, take a breath and begin working on the SIMPLE plan on 

the next page. 



The SIMPLE Plan for Emergency Events: Date:_________ Time:________ 

Name(s) Technician:___________________________________________________________________ 

Facility Emergency Coordinator: ______________________________________________________ 

LANCE and SIMPLE: What happened? Who is at risk? What is anticipated? What is the plan? 

____________________________________________________________________________________ 

What type and amount of problem (fire, overpressure, release – aerosol, dense gas, vapor, liquid)? 

________________________________________________________________________ 

Sources of Ignition: If the release approaches 15,000 PPM, aggressively control sources of ignition. 

Define control of potential sources:___________________________________________________ 

Isolate the Release: Consult P&ID for location of valves to control a potential release; make sure liquid 

isn’t trapped. 

Upstream valve: ___________________________________________________________________ 

Downstream valve:_________________________________________________________________ 

Trapping concerns:_________________________________________________________________ 

Manage the Pressure: Reduce system pressure, reduce cooling demand, isolate the amount of ammonia 

flowing to leak site. 

High Side:_________________________________________________________________________ 

Intermediate:______________________________________________________________________ 

Low Side:_________________________________________________________________________ 

Positive Pressure Ventilation: Plan for the downwind and/or route of your ventilation release. Sources of 

ignition controlled? Fire spread potential? Public safety access, traffic control concerns? 

Inside travel of gases (Building Plan):_________________________________________________ 

Downwind concerns (Site Plan):______________________________________________________ 

LANCE Again: Continuously check in with LANCE and improve upon the plan. 

Recheck LANCE: _________________________________________________________________ 

Notify the local, state and federal environmental regulators: Date/Time/Initials 

Emergency Response Plan: Transition to the 30-Minute Plan; size up, notification, incident action plan, 

safety plan and command and control. 

IAP, Safety Plan, backup staffing, EMS, decontamination, rehabilitation 

Site Plan/Building Plans, P&IDs and Photographs 

18 


PSM Readiness Outline 

1. Employee Participation – A team approach! 

Who is on the team? Engineering, Operations and 

Maintenance, fork lift drivers, general laborers, 

supervisors, managers 

How are you looking at your problems? 

Impacts – priorities – perceived vs. real threats 

Economics – most benefit for the investment 

Tracking and recording problems, challenges, needs 

The cost of a forgotten fix? 

Yearly awareness training – readiness to evaluate 

the facts; focus on making good fixes 

Keep minutes and good records of your efforts 

Employee access to the information (with conditions) 

2. Process Safety Information 

Knowing the chemical and hazards – data book, MSDS 

Understanding your system – P&ID and valve tagging 

Operational SOPs 

Materials, electrical, certification of service relief valves 

Operational limits/capacities, consequences of deviation 

Unobstructed and accessible exits 

Monitoring systems – pressure and release monitoring 

Ventilation systems controls and valve operation 

Compliance to “good engineering practices” 

3. Process Hazard Analysis – site specific 

What if/checklist methodology 

Every piece of equipment (unless exactly the same) 

documented and problems addressed ASAP 

Facility and human factors 

Updated every five years 

4. Operational Procedures 

Clearly documented initial start up, normal operations, 

emergency/normal shut down, start up after turn-around 

SOPs – preventing slugging, trapping, overfilling 

Safety, health, PPE, lockout/tagout, operating limits, 

deviation, safeties, confined space, operator qualification 

Recognizing a problem and tracking its repair 

IIAR Bulletin 107 

Maintenance, review, access, training plan 

5. Training 

Identify who is to be trained and set competency levels 

Awareness, Technician, Operator – Initial and Refresher 

Operator training – efficiency, effectiveness, and safety 

Records and recognition – testing and certifying readiness 

Ammonia properties, refrig. cycle, mechanical integrity, 

normal operations and operating limits, correcting 

abnormal operations, power failure, responsibilities, 

emergency plans, basic electrical, MSDS, etc. 

6. Contractors 

Contractor packet, sign-in, sign-off procedures – readiness 

and tracking; SOP – who is in charge of an emergency 

incident involving contractor-related work, WHAT IS 

THE PLAN, Process Hazard Analysis (PHA) the worst 

case scenario 

7. Pre-Start Review 

Manufacture support; qualified start-ups; 



8. Mechanical Integrity – system and components 

Pressure vessels, piping, valves, controls, emergency shut 

down systems and every refrigeration component 

Log book – safety valves checked – PM schedule 


Planned maintenance, inspection, testing, training, 

documentation, equipment inventory, manufacturer 

details 

Inspections: check sheets, daily inspection/log, oil 

samples, scans, scheduled maintenance 

Operators and technicians must be trained 

Documentation! Deficiency list addressed! 

Annual audit and Preventive Maintenance manuals 

9. Hot Works Permit 

Program – training – discipline – fire and LANCE and 

SIMPLE readiness 

Welding, grinding, and cutting safety checklist 

Procedures: initiating, issuing, performing, and completing 

Hot Work Permits 

10. Management of Change – technical basis for change 

Impact of change on safety and health; time period for 

change; authorization for change 

PHA – MOC – SOP in sync 

Deficiencies and concerns addressed – walk the talk 

Not needed for “replacement in kind” 

11. Incident Investigation 

ALL near misses and incidents investigated – do the PMP 

within 48 hours of the incident; recommendations must 

be addressed in timely manner 

Records and reports – 5-year history 

Investigation team trained and ready to do the evaluation 

Notifications timely and recorded – follow up 

Documentation 

12. Emergency Response 

The ERP – Strategy – PPE/SOP – connection with public 

safety, evacuation alarm systems, meeting places, 

accountability of employees 

Training and readiness to respond – medical, physical 

Training records and follow-up – PMP opportunities 

Spill notification – numbers and readiness forms 

PPE and response equipment readiness 

13. Audit 

Credibility (trained, tested, complete) 

Deficiencies recorded and resolved and documented 

Certify that compliance has been audited at least once 

every three years; include an audit checklist and 

deficiency tracking log 

14. Ammonia Calculations – Know your system! 

System capacities, release amount charts, delivery log 

RMP details/compliance 



20 

Workbook Questions – Safety, Health, Hazard, and Risk 

1. When considering hazard and risk, what are the Three Golden Rules of Safe and Effective Hazard 

Control? 

2. Define at least one “PMP” and “PSM” issues that match the following risks: 

a. Fire in a fork lift in the loading dock: 

i. Prevention: 

ii. Mitigation: 

iii. Preparedness: 

iv. PSM requirements: 

b. Overpressure circumstance in the condenser: 





c. Aerosol release from an oil pot release in the engine room: 





d. Expansion valve leak noticed by a fork lift operator: 





3. Describe the EMS protocols for: 

a. Exposure to 300 PPM vapor 

b. Hit by an aerosol release (clothing frozen to skin) 

c. Droplet of ammonia propelled into an eye 

d. Heart attack 

e. Heat exhaustion 

4. What are the reporting requirements for local, state, and federal regulatory compliance? 


Glove Box Version of the One-Plan Standard for Emergency Response 

Section I—Plan Introduction Elements 

1. Purpose and Scope of Plan Coverage 

2. Table of Contents 

3. Current Revision Date 

4. General Facility Identification Information 

a. Facility name 

b. Owner/operator/agent (include physical and 

mailing address and phone number) 

c. Physical address of the facility (include 

county/parish/borough, latitude/longitude, and 

directions) 

d. Mailing address of the facility 

e. Other identifying information (e.g., ID numbers, SIC 

Code, oil storage start-up date) 

f. Key contact(s) for plan development/maintenance 

g. Phone number for key contact(s) 

h. Facility phone number 

i. Facility fax number 

Section II—Core Plan Elements – 4 Phases of Response 

I. Discovery – Size-up LANCE 

II. Initial Response - SIMPLE 

1. Procedures for internal and external notifications (i.e., 

contact, organization name, and phone number of 

Facility Emergency Coordinator, facility response team 

personnel, federal, state, and local officials) 

2. Establishment of response management system 

procedures for preliminary assessment of the situation, 

including an identification of incident type, hazards 

involved, magnitude of the problem, and resources 

threatened 

3. Procedures for establishment of objectives and priorities 

for response to the specific incident, including: (1) 

Immediate goals/tactical planning (e.g., protection of 

workers and public as priorities); (2) Mitigating actions 

(e.g., discharge/release control, containment, and 

recovery, as appropriate); (3) Identification of resources 

required for response 

4. Procedures for implementation of tactical plan 

5. Procedure for mobilization of resources 

III. Sustained Actions: 30-Minute Plan/IAP/Safety Plan 

IV. Termination and Follow-Up Actions 

Section III-Annexes 

Annex 1. Facility and Locality Information 

a. Facility maps 

b. Facility drawings 

c. Facility description/layout, including identification of 

facility hazards and vulnerable resources and populations 

on and off the facility that may be impacted by an incident 


Annex 2. Notification 

a. Internal notifications 

b. Community notifications 

c. Federal and state agency notifications 

Annex 3. Response Management System 

a. General 

b. Command 

(1) List facility Incident Commander and Qualified 

Individual (if applicable) by name and/or title and 

provide information on their authorities and duties 

(2) Information (i.e., internal and external communications) 

(3) Safety 

(4) Liaison—Staff mobilization 

c. Operations 

(1) Operational response objectives 

(2) Discharge or release control 

(3) Personal Protective Equipment 

(4) Assessment/monitoring 

(5) Containment 

(6) Recovery 

(7) Decontamination 

(8) Non-responder medical needs including information on 

ambulances and hospitals 

(9) Salvage plans 

d. Planning 

(1) Hazard assessment - facility hazards identification, 

vulnerability analysis, prioritization of risks 

(2) Protection 

(3) Coordination with natural resource trustees 

(4) Waste management 

e. Logistics 

(1) Medical needs of responders 

(2) Site security 

(3) Communications (internal and external resources) 

(4) Transportation (air, land, water) 

(5) Personnel support (e.g., meals, housing, equipment) 

(6) Equipment maintenance and support 

f. Finance/procurement/administration 

(1) Resource list 

(2) Personnel management 

(3) Response equipment 

(4) Support equipment 

(5) Contracting 

(6) Claims procedures 

(7) Cost documentation 

ADDITIONAL INFORMATION – NOT GLOVE BOX 

Annex 4. Incident Documentation 

a. Post accident investigation 

b. Incident history 

Annex 5. Training and Exercises/Drills 

Annex 6. Response Critique and Plan Review and 

Modification Process 

Annex 7. Prevention 

Annex 8. Regulatory Compliance/Cross-Ref. Matrices 



Initial and Sustained Response: “Coordinate with public safety to create a safe and 

methodical response plan” 

Important NOTE: Your written Emergency Response Plan and all supporting SOPs should be 

completed, adopted and formally in place BEFORE the emergency event. This is the value of 

PREPAREDNESS for emergency response. 

Define Strategy: Identify the downwind/downstream threats and the degree of concern; determine the 

strategy for control after considering the strength and availability of on-site facility and public safety 

response capabilities. Meet with the local fire department and consider the Leak Control SOPs for the 

following concerns: 

• Defensive Strategy: Performing LANCE and SIMPLE within levels below the IDLH (300 PPM) 

and engaging incidental response safely in IDLH atmospheres, as defined within the facility 

Emergency Response Plan. 

• Offensive Strategy: Define which of the following offensive strategies you intend to perform: 

rescue, reconnaissance, isolation, containment, control, and/or product management; determine the 

level of PPE and entry PPM levels for responders and review the use of P&ID and Leak Control 

SOPs. The Safety Officer, Facility Emergency Coordinator and/or the Incident Commander shall 

assess the timing of the entry with the hazards and risks associated with the entry; provide back-up 

staffing; assess entry team physical, mental and PPE readiness; develop a written IAP and Safety 

Plan that clearly define the entry objectives, PPE, and personnel accountability when entering at 

levels that could reach or exceed 5,000 PPM. 

• Form a Unified Command between on-site Facility Emergency Coordinator and the public safety 

Incident Commander. Assess whether you will be engaging public safety for entry to achieve 

specified offensive strategies (described herein), valve control, back up, support (decontamination, 

safety, rehab, EMS). Describe how the on-site and public safety response teams will coordinate, 

e.g. facility operation of system controls supported with back-up from public safety or public 

safety operation of system components as advised by facility response team members located 

outside of the hot zone. 

• Use personal protective equipment (PPE) based upon the strategy set in the Emergency Response 

Plan. Make sure to address service and maintenance, leak investigation, incidental response, 

defense, offense, and support systems (decontamination, downwind/downstream monitoring, etc.). 

The back-up system for entry should also be defined; 1 in 1 out for investigation and incidental 

response; ASTI recommends 2 in and 2 out for emergency entry to levels that exceed 300 PPM. 

Size up: Recite LANCE and SIMPLE; describe current status. What happened? Who is at risk? What do 

you expect will happen? What plan do you recommend? What is the nature and type of release? (dense 

gas and/or streaming aerosol, vapor, liquid – incidental, out of control, or peaked and recovering) 

Set the Zones and Control Access: Hot Zone >300 PPM; Warm Zone access route out of the Hot Zone < 

300 PPM; Cold Zone (0 PPM). ASTI recommends that command post, EMS support, and Rehab be 

placed at least 150 feet upwind in the Cold Zone. Control access to property and downwind (coordinate 

with public safety) - 1 in and 1 out for under 300 PPM and 2 in 2 out for entry to levels >300 PPM. Decon 

should occur in Warm Zone. Those performing decon must wear PPE at least one level below those being 

decontaminated; the decon process will cause vapor to gas off. 

Incident Action Plan (IAP) and Safety Plan: Write an IAP and Safety Plan and set up zones and 

controls, decon, rehab and EMS assignments when your plan involves entry for “offensive” actions. 

Termination of the Incident: Maintain a minimum of 1 in and 1 out back-up and appropriate PPE as 

would be used for IDLH atmosphere until the re-start process is completed and the system is working 

properly. 

22 



Containment: When ammonia aerosol releases are covered with a tarp (or otherwise contained), the 

contained area significantly cools down and the reduced temperature will also reduce pressures within the 

system or vessel holding the ammonia supply. Be aware that the aerosol spray will deflect against the 

containment tarp and form a pool of liquid ammonia. 

Summary of Response Strategy, Tactics, and PPE Considerations 

Note: Read each Response Strategy from left to right across the table 

Strategy Tactic(s) Pers. Prot. Equip. Special Concerns 

Incidental Control: 

Implemented at 

< 300 PPM; 

This strategy is 

NOT an emergency 

event 

Implementation of 

LANCE and 

SIMPLE inside the 

Hot Zone >300 

PPM to accomplish 

rescue, 

reconnaissance, 

control, 

containment, 

product movement, 

etc. 

Rescue within the 

standards of the 

PPE and training 

Offensive Entry to 

control and contain 

the release 

Use the refrigeration control 

systems outside of the Hot 

Zone to manage the release: 

compressor control, remote 

isolation valves, electrical 

system controls, ventilation 

controls, etc. Contain the 

release – close doors 

-Follow the guidance provided 

within facility-adopted 

Emergency Response Plan 

and adopted SOPs 

-Continuous atmospheric 

monitoring required 

- Evaluate the risk BEFORE 

developing an entry plan; 

consider the phase of the 

release: incidental, out-ofcontrol, 

peaked, or 

recovering 

-Do aggressive LANCE and 

SIMPLE 

-Communicate with the victim 

-Advise location and condition 

of victim; engage ventilation 

support for the victim 

-Training, and ability to 

search, rescue/carry the 

victim 

-Written Incident Action Plan 

and Safety Plan 

-Entry team must be clear on 

task assignments; keep tasks 

short (10 min.); make sure 

the plan is clear and 

achievable BEFORE 

allowing entry 

Air purifying respirator or 

SCBA, ammonia monitor, 

radio, safety boots, helmet, 

and full skin protection; 

continuous atmospheric 

monitoring required 

SCBA, ammonia monitor, 

radio and level A or B PPE 

-Level B 5,000 PPM 

-Flash protected at >15,000 

PPM for an inside release 

-Thermal rated -87ºF dense 

gas and -100ºF for working 

in an aerosol stream 

-NIOSH approved 

permeation rated for 

aerosol 

-Atmospheric monitoring 

and PPE required for the 

rescuer as certified, fit 

tested, medically cleared to 

use SCBA 

-2 in 2 out coverage 

recommended 

-PPE for search and rescue 

team and for the victim 

-Atmospheric monitoring 

and risk assessment 

required to determine the 

proper PPE (as described 

within this column) 


required 

Follow incidental response 

guidance provided within the 

plan; 1 in 1 out coverage; keep 

exit available for escape and 

back off when a life threat or 

when immediate control is not 

readily available and safe to 

accomplish. 

-Keep exit available for escape 


recommended 

-Fire hose line in place for 

safety and support for 

potential fire risk 

-When the release is 

recovering and SIMPLE is 

engaged, entry can be 

considered at


24 

ERP ASSIGNMENTS TO IMPLEMENT INCIDENTAL AND EMERGENCY EVENTS 

Role Responsibility Name(s) and/or Job Title 

On Site Incident Commander FEC is in charge of implementing the Name: Job Title: 

(IC) or “Facility Emergency facility emergency response plan and 

Coordinator” (FEC) 

coordinates with public safety IC who 

oversees the entire incident action plan; 

must be trained and annually certified 

at the Hazmat Technician level plus 

trained on the Incident Command 

System, with good understanding of 

how to enter into Unified Command 

Safety Officer (SO) In charge of developing and 

implementing the safety plan and must 

be trained and annually re-certified at 

the Facility Emergency Coordinator 

level 

Ammonia Specialist/Non 

Entry; this position can 

assume Safety Officer (SO), 

Plans Officer (PO), and/or 

Operations Chief (OC) 

Maintenance, service, and leak 

investigation at levels below 

IDLH; skill tested, fit tested 

and medically cleared for use 

of an air purified respirator 

above 25 PPM and below 300 

PPM” 

Entry Team Members certified 

(skill tested, fit tested and 

medically cleared) above 300 

PPM and below 5,000 PPM 

(Level B PPE) 

Emergency Response Team 

Support Role: 

Decontamination Team 

(Decon); Rehabilitation Team 

(Rehab); Emergency Medical 

(EMS); Logistics Team (Log); 

Environmental Team (ET); 

Evacuation Coordinator Lead 

(ECL); Evacuation 

Coordinator (EC); 

Finance Officer (FO); Legal 

Officer (LO); Documentation 

Team (DT); Liaison (L); 

Public Information Officer 

(PIO); Notifications 

Coordinator(NC); Security 

Control Officer (SCO) 

Trained at the Facility Emergency 

Coordinator or Hazmat Tech. level but 

cannot participate with the Entry Team; 

defensive tactics; must be trained and 

annually re-certified – not certified to 

use PPE or to be a part of an entry team 

Emergency Response Team members 

with personal protective equipment to 

enter an environment between 50 PPM 

and 300 PPM; must be trained and 

annually certified to the First 

Responder Operations Level or as 

Hazmat Technician 

Entry team members who are trained 

and certified to enter at Level B PPE 

circumstances; must be trained and 

annually certified as Hazmat 

Technicians 

Plays a specified role on the 

Emergency Response Team and has 

been skill tested to perform that role; 

ASTI recommends that all Emergency 

Response Team Members receive 

Hazmat Technician level training and 

that they annually refresh and certify in 

the roles that they play. 

Command Team members listed in this 

row are specialists in their own fields 

and need only be aware of and skill 

tested for their emergency response 

role annually. 

Name: Job Title: 

Identify the specialty by designating 

the name with the abbreviation listed 

in “Role” Column: 


Identify the Entry Team Leaders by 

designating the name with ETL: 


Identify the Entry Team Leaders by 

designating the name with ETL: 


Identify the specialty by designating 

the name with the abbreviation listed 

in “Role” Column: 




Summary Reminders for Emergency Response: 

• Communicate with facility operations Facility Emergency Coordinator to establish if the problem is 

“incidental” or if an actual emergency exists – note the location, nature, and timing of the release. 

Take a digital picture if safe to do so. 

• Monitor incident conditions and follow the ERP and Evacuation or Shelter-in-Place policy. 

• Establish a Safety Plan with zones and controls for the Hot Zone and make sure that proper PPE is 

being worn and the buddy system is enforced in the Hot Zone. Continue monitoring the atmosphere, if 

levels exceed the ERP standard you must exit the room. 

• Reference the Emergency Response Cards and Emergency Response Plan and develop a written 

Incident Action Plan and Safety Plan. Consider a downwind/downstream and control/containment plan 

of action. 

• Always use the buddy system. Have a backup entry team ready before entering the room and notify 

the Incident Commander when accomplishing the IAP objectives. Use “one in one out” for incidental 

control; “two in two out” is recommended for emergency response entry. 

Evacuation/Shelter in Place: Evacuated personnel will move laterally and upwind to pre-arranged 

assembly points, if possible, as soon as possible as guided by the Facility Emergency Coordinator and 

those he/she assigns to coordinate the evacuation. People located in the office and warehouse should 

evacuate and assemble at the designated evacuation meeting points. Wind direction and the actual location 

of the ammonia release will determine the best location of the evacuation gathering point. Once 

assembled, verify the head count and make sure that all employees, trucker drivers, visitors, and 

customers are accounted for. Personnel will remain at this location until released by the Plant Manager, 

Foreman or Lead Supervisor. Do not evacuate through a gaseous cloud or aerosol of ammonia; retreat to a 

shelter location where the doors and windows can be closed and the heating, ventilation and air 

conditioning systems can be shut down. Stay in “shelter in place” mode until contacted by the incident 

commander or when instructed to move out by evacuation coordinators. Stay tuned to the local emergency 

broadcast system on the radio. 

Regulator Notification: If the leak has been identified as being an RQ (Reportable Quantity 100 pounds 

of ammonia within 24 hours), report to your NRC (National Response Center) within 15 minutes of 

discovering the release (unless you are conducting life-critical response protocols). Local and State 

notifications are also required as listed in the State and Local emergency response plans. Most local and 

state regulators require a more immediate notification than the NRC guidelines. Your ERP should define 

the notification requirements more specifically. 

Incident Command System: During an ammonia emergency, the Facility Emergency Coordinator will 

assume initial control of the incident and implement the Incident Command System (ICS); the first public 

safety officer on the scene will assume the Incident Commander role (as determined in your Emergency 

Response Plan) and will oversee on-site and off-site emergency concerns. The response strategy and 

tactics will be implemented by using an incident action plan and safety plan. Command position 

descriptions and ICS approved response forms are located at the end of this document. 

Emergency Incident Information: The Facility Emergency Coordinator and Incident Commander will 

develop criteria regarding the information to be released about the status of the incident. Priority will be 

placed on releasing information that facilitates an effective response to and recovery from the incident, 

including concerns for those who are in shelter-in-place mode or potentially in harm’s way. The facilityspecific 

information should be held in confidence and used only to improve future operations. Those 

releasing information must be clear, honest, and straightforward in their communications on experiences 

that occurred during the incident. Details and suppositions regarding specific actions by those involved 



with the incident should be discussed in a privately held debriefing after the event; the focus should be on 

how to prevent, mitigate and prepare for future response concerns. The designated information officer or 

Incident Commander is the only person authorized to make statements to or answer questions from the 

news media regarding the emergency. All media personnel requesting statements or interviews with 

facility management will be directed to the facility CEO who will limit feedback to maintain consistency 

with the communications from the Incident Commander and will uphold the corporate policy on public 

news releases. Be sure to obtain executive management permission before releasing any information 

gathered during an emergency response or response debriefing. 

Terminating the Emergency: Establish a re-start plan with adequate PPE, zones and controls, 

operational considerations, and safety management; monitor the operating condition of the equipment 

during re-start. This phase of response is often the most dangerous because responders and system 

operators “drop their guard” when restoring the facility and equipment. The actions taken during the 

restart, service, repair, salvage, clean-up or overhaul of damaged equipment and facilities must follow 

proper precautions (PPE and SOP guidance). Treat the situation like a live incident. Everything is “hot” 

and everything must be double-checked. Lock out and tag out, and all system safety requirements MUST 

be considered as high priority responsibilities. The system has experienced stress and the potential for 

another emergency event is possible. This level of concern must prevail until the system is cleared by the 

chief operator as being safe and conforming to normal operating specifications. 

Incident Debriefing: The Incident Commander will review, debrief, summarize, and prepare a follow-up 

report of each incident. The verbal debriefing should honestly evaluate what could have been done to 

improve the incident outcome. Leaders should be honest and frank in the discussion, placing no blame, 

and should highlight the experiences and any mistakes as learning opportunities. Any changes (with focus 

on better prevention, mitigation, preparedness and response/recovery readiness) should be written as 

recommendations that are prioritized for follow up. These recommendations will be addressed as soon as 

possible; life hazards and code violations should be complied with immediately. Each change made will 

be dated and signed when completed. Note: Obtain executive management permission before releasing 

any information gathered during an emergency response or response debriefing. 

WORKBOOK 

Diagram what your command structure should look like at the initial action and sustained action 

phases. Also diagram an incident showing command post, evacuation points, decon, rehab, hot, warm 

and cold zones 

ICS Command Structure 

26 

Incident Diagram 

◄Locked Gate 

Building 

▲ 

NH3 

Wind ▲ 

Access Gate ► 


Workbook Questions – Emergency Response 


1. Explain, in your own words, how you would transition from “incidental response” to emergency 

response. 

2. Describe your actions for the four phases of an emergency incident: 

a. Discovery 

b. Initial Response 

c. Sustained Response 

d. Termination 

3. Describe the strategy and level of PPE in your facility response plan in the appropriate boxes: 

Strategy Personal Protective Equipment (PPE) 

Evacuation only and implement LANCE and SIMPLE? ASPE Gear? 

Defense – Incidental Response? ASPE, Level B or Level A? 

Offense – Entry for rescue, reconnaissance, control, 

containment, product management? 

Offense with Unified Command with public safety? 

Other: 

Level B and/or Level A? 

Level B and/or Level A? 


Other: 

4. Describe the critical elements associated with each of the following issues: 

a. Ammonia pipelines: 

b. Key positions of a basic command team (using ICS): 

c. Termination phase concerns: 

d. Zones and Controls: 

e. Safety Plan concerns: 

f. Key incident support functions:


DISCLAIMER 

The Ammonia Safety and Training Institute (ASTI), as well as the host, sponsors, vendors, and others associated with 

conducting Safety Day Training or who otherwise utilize this Workbook disclaims liability for any personal injury, property, or 

other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly 

resulting from the publication, use of, application, or reliance on this publication. This disclaimer includes the fact that those 

who use the materials contained within this Workbook make no guaranty or warranty, express or implied, as to the accuracy or 

completeness of any information published herein, and disclaim and make no warranty that the information in this publication 

will fulfill any of your particular purposes or needs. 

In publishing and making this publication available, ASTI and those who use this Workbook are not undertaking to render 

professional or other services for or on behalf of any person or entity, nor are we undertaking to perform any duty owed by any 

person or entity to someone else. Anyone using this document should rely on his or her own independent judgment or, as 

appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given 

circumstances. 

28 



Workbook Answers - Ask SAL Monia – Chemical and Physical Traits 

Meet SAL Monia – Some Friendly and Live Saving Advice 

1. What is the significance of SAL’s name? What are his “two very different sides”? 

Self Alarming Liquid – SAL is the world’s most popular chemical – refrigerant preserve food, fertilizer 

and produce food, treat water, clean floors helps in making many important products – paint to ceramics; 

and environmentally friendly natural refrigerant of choice; also a real “challenging character – a real 

stinker”! 

2. Why is SAL a “challenging character” to humans; a real “stinker”? 

Feared by those who don’t know or understand him and easy to detect when he gets free; dangerous to the 

ignorant 

3. What is SAL’s warning to those of you who work on ammonia systems? What’s he say about you 

“messing with the system”? 

All pipelines pressurized and double check position of upstream/downstream; handle those valves with 

care; If you don’t know then don’t go! 

4. SAL mentions that when operators don’t respect him and work on his system without PPE or 

proper SOP he “spits out an aerosol spray with a freeze burn” – What’s the lesson in that 

statement? 

SAL can blind or asphyxiate those caught in his trail…be ready, wear PPE, and know the status of the 

system BEFORE you work on it! Keep clear of the system when you don’t know what is going on. 

Chemical and Physical Characteristics Get to know SAL 

5. Why is SAL “so darn thirsty”? Where does he find water? What forms when he mixes with water? 

Anhydrous ammonia means that he has no water and he wants water…he’s very thirsty! He will find it 

anywhere and humans have plenty – eyes, mouth, nose and even in “places that human’s find 

uncomfortable” like the GROIN! He mixes to form ammonium hydroxide which is caustic and burns. 

6. What are the four types of ammonia releases that emergency responders should be aware of? 

Liquid, aerosol dense gas or aerosol stream, or as an “invisible vapor” 

7. What happens when you raise SAL’s temperature? What happens to his temperature when you 

lower his pressure? Why does this happen? At what temperature does SAL sleep? Can he get 

colder than his boiling point? Why? 

Raise temperature and pressure raises correspondingly; lower pressure and the vapor spreads and cools 

down; because heat energizes the ammonia atoms and makes them move faster – when confined in a tank 

or vessel this builds up pressure; when open to the atmosphere the increase in heat speeds the 

vaporization, the temperature of the liquid and the vapor will cool to below boiling point to near -100 

degrees F. 

8. How does SAL become more powerful? When is he more dangerous? What gives SAL power to 

expand? What’s it take to contain SAL? What happens when emergency response personnel cover 

him with a tarp? 



Increase pressure, temperature or volume of the release and SAL becomes more powerful; as he grows in 

size he becomes more dangerous to the downwind; heat and wind give SAL the power to expand 

downwind; containing him is as simple as closing the door on the release, or when outside the emergency 

responders may throw a tarp over him, his cold temperature meets the tarp which shields the warm air and 

he condenses into a liquid and aerosol gas 

9. What happens to the vapor as it escapes downwind? What happens when SAL’s vapor hits the 

buildings in the downwind? How do humidity and the landscape affect his release? How would a 

person escape an ammonia release? What brings him back to earth? 

The heated air will cause SAL to rise and escape to the upper atmosphere where temperatures are cold and 

pressures are low – his home in the sky where he relaxes and goes back to his natural state as nitrogen and 

hydrogen. When his vapor cloud hit’s a building the heat of the building repels him and he bounces 

around and rolls over the top (unless sucked inside by the ventilation system). Humidity – remember he is 

VERY thirsty and he will stop for a drink before escaping; at that point he becomes very heavy buoyant 

cloud that will crawl along the earth’s surface. When he goes to his home in the sky it’s only that bold of 

lightening and rain that brings him back to earth (very similar to how he is made industrially with the 

Haber/Bosch process – heat, pressure, and catalyst) 

Using Ammonia Systems with PPE 

10. Why does SAL need a vapor space when contained in a pipe or vessel? What’s it mean when SAL 

“pops the cork so to speak”? What happens to the system that might allow SAL to escape? What if the 

cloud is covering all escape routes? 

Vapor space of at least 20% to allow for liquid expansion; when pressures continue to rise SAL will 

eventually pop the cork by releasing through a relief valve, or breaking through a system component; rust, 

corrosion, leaky valve, or operator error are the usual reasons why SAL escapes. 

11. What’s SAL’s warning about being caught in a release? What is olfactory fatigue? How does SAL 

recommend that you escape? What are the key concerns about proper shelter in place tactics? 

Stay away from the system unless you know what you are doing and have PPE, training and you know 

what you are doing; follow procedures and stop SAL when he is small. Olfactory fatigue occurs to the 

nose sensors (little hairs) that tells you when ammonia exists; when those nose hairs are burned out they 

can’t smell and so you aren’t able to heed the warning and that’s when SAL is liable to “take you out” 

don’t be a tough guy! Escape SAL by moving around SAL, move lateral, upwind or shelter in place; 

close doors, windows, ventilation system, tape off windows with duct tape and plastic. 

12. What should you do if SAL gets on you? What happens to the skin tissue? What is SAL’s warning 

about an aerosol burn? How long should you flush with water? Should you rub the burn area? Why are 

your eyes so vulnerable to injury by SAL? What is SAL’s recommendation? 

Wash SAL with water, draw him out of your tissue with 15 to 30 minutes of water; the skin tissue freezes, 

shrinks and becomes damaged by the caustic and freezing affect of SAL’s burn; an aerosol may freeze 

clothing to your skin so thaw with water before removing; don’t rub the area allow the water to draw SAL 

out; also be prepared for the off-gas when you begin washing ammonia from a person; that’s why it is 

good to get clothes that aren’t frozen off before starting water. Eyes have a very thin skin covering an 

eyeball full of liquid; one drop propelled into the eye can cause blindness; use goggles or better yet a full 

face respirator. 

Hazards and Risks 

30 



13. What is SAL’s warning when large amounts of his vapor enter a confined room with no ventilation? 

What is needed for SAL to ignite into a powerful ball of flame? What’s this called? 

When vapors reach somewhere around 15% to 25% of a mixture in air (150,000 to 250,000 PPM) a source 

of ignition that is at least 1204 degrees F may ignite him into a powerful ball of flames called a “flash 

fire” or deflagration. 

14. What is SAL’s warning about water? Why is he more sensitive when water is dumped on him rather 

than for him to jump into the water? 

SAL doesn’t like to be startled with water being dumped on his cool liquid (water on an ammonia vapor is 

not the same, the vapor will attract to the water rapidly; but an aerosol or liquid is very hard to control 

with water – the vapors tend to become caustic and heavy, staying close to the ground); he is settled down 

and asleep and suddenly the hot flash of water will make him spit with anger; he likes water and is much 

more easy to control when he goes to water rather than vice versa. 

LANCE – The super hero! 

15. What does L.A.N.C.E. stand for? 

L = Life Safety – set the hot zone and check PPE 

A = Alert the response team and let those in the immediate area know that there is a problem 

N = Notify 9-1-1 by following your SOP 

C = Contain the release; close the door; when trained control the release if safe to do so 

E = Escape, Evacuate or Shelter In Place 

Injury Prevention & Health Concerns 

16. What does LANCE say regarding the value of PMP (Prevention, Mitigation, and Preparation)? What 

type of personal protective equipment (PPE) should an operator wear when working around the 

ammonia system? What’s the immediate area of concern should a problem develop while working on 

the system? 

The best way to stop an emergency is to prevent it from occurring; operators should wear full skin 

protection, radio, ammonia monitor, gloves, respirator (or face shield or chemical safe unvented goggles); 

10 to 15 feet of immediate impact from a sudden release. 

17. What is the lowest level that most people can smell ammonia? What is the PEL for SAL? _______ 

PPM and what does that mean? What is the IDLH: ______ PPM and what does that mean? 

The odor of ammonia can be as low as 5 PPM as far away as a mile downwind (olfactory fatigue or 

damaged nose sensors would reduce the potential to smell small amounts of ammonia). The PEL is 25 

PPM in California and a few other states; the PEL is the point at which everyone should evacuate except 

those trained and equipped to handle the emergency event; the IDLH is 300 PPM (survivable but very 

uncomfortable); the level of PPE must move to self contained breathing apparatus and a chemical resistant 

suit. 

Evacuation and Emergency Medical 

18. What’s the biggest worry associated with approaching an ammonia cloud? Identify three choices you 

have when escaping an ammonia release that continues to get worse (stronger and more irritating 

odor)? Identify three different emergency response leaders you would attempt to contact should you be 

trapped inside and unable to escape an ammonia release? How would you communicate with them if 



you did not have a radio? What are four things you can do to protect yourself during an ammonia 

release that is threatening your shelter in place location? 

Move out and around the release, lateral and upwind; three choices; close the door to contain the release; 

three leaders in the order of contact would be Evacuation Coordinator, Facility Emergency Coordinator, or 

Incident Commander; use the radio or telephone, contact 9-1-1 center to get word to the Incident 

Commander; water will help you, a wet cloth or a shower of water will attract the ammonia vapor (not 

good for putting on liquid or aerosol) to slow it’s attack on humans; 1) keep moving lateral 2) move to 

shelter in place 3) put wet cloth over your face and keep going 4) radio or call for help 

19. How does your body react when it takes in a lot of ammonia vapor? At what point does the level of 

ammonia cause your breathing to stop? Why does this occur? Identify four steps to helping a person 

who has just met you after escaping through an aerosol ammonia release? What would you do if the 

person swallowed some ammonia liquid? 

You feel ammonia in the nose, throat, and as it gets worse, in your chest; when you escape to the outside 

breathe deeply; if your lungs or chest hurt you should seek advanced medical care and a doctor’s care; at 

1,500 PPM we begin coughing uncontrollably and at 1,700 PPM our breathing stops (as if we have 

something caught in the throat; four steps 1) call 9-1-1; 2) remove clothing unless frozen and then wash 

with water; 3) 15 to 30 minutes of washing with water – no rubbing; 4) medical surveillance for those who 

are experiencing problems with their breathing; drink water, milk, orange juice if the person is conscious, 

don’t allow vomiting, seek advanced medical care. 

The SIMPLE Plan 

20. How much more at risk is the person who is within 10 to 15 feet of an initial release of ammonia from 

experiencing serious injury or death than for the emergency responder or the downwind population? 

What is LANCE’s recommendation about avoiding the threats of an ammonia release? What’s 

LANCE’s recommendation about ammonia and its mixture with chlorine? What’s the threat of 

ammonia soaking into the ground? What does the term S.I.M.P.L.E. mean? 

A person is at least 5 times more at risk to serious injury or death when within 10 to 15 feet of the release; 

follow repair, maintenance, service, and leak SOP when working on the system; LANCE recommends 

that operators wear PPE, always know where the exits are; and contain the release upon escape; LANCE 

warns that Chlorine and Ammonia mixture is very toxic and potentially explosive; too much ammonia on 

the ground can migrate to drinking water and cause problems for infants, infirm and older humans; the 

SIMPLE logic is defined below 

S = Sources of Ignition controlled 

I = Isolate the release upstream and downstream 

M = Manage the pressure 

P = Positive Pressure Ventilation with a plan for the downwind vapor exhaust 

L = L.A.N.C.E. again 

E = Emergency Response Plan – develop an Incident Action Plan and Safety Plan 

32 



ASTI Final Exam – 24 Hour Technician 

Name: _________________________________________ Date: _____________________ 

Course Location: ___________________________________________________________ 

Company Name: _____________________________________________________ 

Circle True (T) or False (F) to the following questions: 

1. T F Anhydrous Ammonia (NH3) is considered a highly corrosive 

alkaline, and on the lower half of the pH scale at 4. 

2. T F A method of containing an ammonia release in an engine room may be as 

simple as closing a door. 

3. T F The initial “size-up” has no significance on the final outcome of an Ammonia 

release response. 

4. T F It is extremely important to initiate water flushing as a method of 

decontamination immediately, or as soon as possible, to someone contaminated by 

Ammonia liquid or aerosol. 

5. T F An Incident Commander/Scene Manager, and trained and properly equipped 

technicians working from the facility Emergency Response Plan and utilizing an 

Incident Action Plan and Safety Plan are essential at the emergency response scene. 

6. T F Having a decontamination station set-up is a required protocol of the 

Emergency Response Plan. 

7. T F It is permissible for a Scene Manager to direct an employee to complete 

a task that is beyond his/her level of training during an emergency. 

8. T F The facility Scene Manager who in-charge of an incident, prior to public 

safety Incident Commander arrival, only needs to be certified with a 24 

hours of First Responder Operations training requirement. 

9. T F During the Discovery and Initial Response phases of an emergency it is 

recommended that LANCE be performed, take a breathe, then consider a SIMPLE 

plan before documenting an IAP and Safety Plan. 

Page Two 



10. T F The decision to allow the emergency ventilation system to operate, or not, 

may depend on the downwind threats, need for rescue, and flammability 

concern. 

11. T F Personnel required to wear air-purifying respirators need to be fit-tested 

every three years. 

12. T F An ammonia release contained inside a building would not pose as much 

concern to the surrounding community if that release is ventilated with a plan for 

the downwind. 

13. T F Ammonia is labeled as a non-flammable gas by the D.O.T. even though 

it will burn between 16% and 25% mixture in air. 

14. T F An offensive emergency response requires that a facility has in-place a 

comprehensive Emergency Response Plan which identifies the roles of 

players and procedures 

15. T F Facilities are required by Federal law to report several small releases, 

e.g. 30 lbs, 40 lbs, and 50 lbs, if the total ammonia release exceeds a 100 pounds 

in any 24-hour period; local notification requirements may be more stringent than the federal 

requirements. 

16. T F A defensive response plan require facility personnel to evacuate upwind, 

or Shelter-in-Place in the downwind, and attempt to control pressure, and isolate 

the release from safe locations outside of the release area. 

17. T F OSHA safety requirements establish that a minimum of eye glasses is all 

that is needed while conducting maintenance of an ammonia system. 

18. T F Annual meetings and training with your local public safety agencies is 

an important step in emergency response planning compliance. 

19. T F Any visible aerosol producing a dense anhydrous ammonia cloud 

should be considered dangerous and possibly an explosive event. 

20. T F Personnel can continue to work for an unlimited time in ammonia 

atmospheres that exceed thirty-five (35) ppm. 

21. T F A dense cloud or visible aerosol Ammonia release will first absorb 

moisture and hang at low levels prior to vaporizing off and rising. 

22. T F A victim hit by an aerosol may have swelling of the trachea. 

. 

Page Three 

Fill in the Correct Answers: 

1. L.A.N.C.E. is an acronym that stands for: 

34 


L___________________________________________________ 

A___________________________________________________ 

N___________________________________________________ 

C___________________________________________________ 

E____________________AND/OR S______________________ 


2. It is permissible to utilize a cartridge mask respirator when air monitoring reveals the ammonia level is 

lower than ______________ ppm. 

3. S.I.M.P.L.E. is an acronym that stands for: 

S ________________________________________________________ 

I ________________________________________________________ 

M _______________________________________________________ 

P ________________________________________________________ 

L ________________________________________________________ 

E ________________________________________________________ 

4. Place in order the following concerns as it relates to an Ammonia response (“A” is the highest priority 

with “C” being the lowest); Environment, Life Safety, Equipment 

A._____________________________ 

B._____________________________ 

C._____________________________ 

5. The National Response Center (NRC) shall be notified within ________ (minutes) of a reportable 

ammonia release of __________ lbs. or more. 



Page Four 

6. Identify three of the eight priority concerns that would allow you to address an “incidental release” 

rather than consider the release as an emergency event. 

36 

1. ___________________________________________________ 

2. ___________________________________________________ 

3. ___________________________________________________ 

7. Circle the two correct answers: Which of the following is a required procedure of the Emergency 

Response Team prior to executing an entry into an ammonia release? 

a. Having the boss present 

b. Monitoring of release conditions 

c. Having three back up entry teams ready 

d. Position a back up for the entry team responders 

8. Flushing an ammonia burn with water is the preferred method of minimizing trauma and should be 

used for a minimum of __________ minutes, however __________ minutes is preferred. An incident 

of this nature will require medical assistance, call 911! 

9. The combustible level of Ammonia should be considered to be between _________ % 

and _____________ %. 

10. The 30 Minute Plan identifies response reminder checklists for the four phases of an 

emergency event. What are those phases? 

D _______________________________________ 

I ________________________________________ 

S ________________________________________ 

T ________________________________________ 

11. What are two key issues to be concerned about during the Termination Phase of an 

emergency event? 

1. _____________________________________________________________ 

2. _____________________________________________________________ 

Visit us on the web at ‘ammonia-safety.com’ 


2008 SAFETY DAY EVALUATION 


We appreciate and benefit from your evaluation and comments. Please place your choice 

of the 1 to 5 rating: 1 - Poor, 2 - Needs Work, 3 - Okay, 4 - Very Good, and 5 - Excellent: 

Topic 

Quality of Instruction - Overall 

Chemical and Physical Characteristics 

Hazard and Risk 

Safety and Health 

Discovery and Incidental Response 

Emergency Response 

Incident Command 

The "One Plan" 

Quality of Setting 

Staff Support 

Instructor Engagement (helpfulness) 

1 - Poor 2 – Needs 

Work 

3 - Okay 4 – Very 

Good 

We appreciate any written comments that you have to offer – help us get better! 

5 -Excellent 

Signature: _________________________________________________________ 

Optional: 

Phone: ________________________ Email: __________________________ 

THANK YOU!!!

Awareness Training Goals - Salinas Valley Ammonia Safety Day

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