Stationary Ammonia Operator The Stationary Ammonia Operator is responsible for the safe, efficient, and code-compliant operation of industrial ammonia refrigeration systems at a distribution center or ammonia plant in the State of Texas. This position requires comprehensive knowledge of ammonia refrigeration mechanics and full compliance with Federal OSHA Process Safety Management regulations (29 CFR 1910.119), EPA Risk Management Program requirements (40 CFR Part 68) as administered in Texas by the TCEQ under the Texas Clean Air Act, TCEQ air permit requirements under 30 TAC Chapter 106, ASHRAE Standard 15, and IIAR standards. The operator shall maintain meticulous inspection and maintenance records meeting both federal and Texas state requirements and must be prepared to respond to OSHA Region VI or TCEQ compliance inspections.
Minimum Qualifications:
Education & Certification High school diploma or GED required; Associate's degree in HVAC/R, Mechanical Technology, or related field preferredEPA Section 608 Universal Certification — required by federal law for handling regulated refrigerantsRETA CARO (Certified Assistant Refrigeration Operator) or CIRO (Certified Industrial Refrigeration Operator) preferredOSHA 10-Hour or 30-Hour General Industry certification preferred (Federal OSHA standards apply in Texas)TDLR ACR Contractor License (Class A — Process Cooling) preferred if performing maintenance/repair work not covered by the industrial exemption; or verification that the industrial-operation exemption under Texas Occupations Code §1302.052 applies to the position Hazardous Materials First Responder — Operations Level (29 CFR 1910.120 / NFPA 472) or higher Valid Texas driver's license If working within the City of Houston: Stationary Engineer's License (applicable grade) as required by Houston city ordinance ExperienceMinimum 2–5 years of experience operating industrial ammonia refrigeration systems Experience in cold storage, food processing, or distribution center environment preferred Demonstrated working knowledge of OSHA PSM (29 CFR 1910.119) and EPA RMP (40 CFR Part 68) compliance Familiarity with TCEQ permit requirements under 30 TAC Chapter 106 preferred
Knowledge, Skills & Abilities:- Thorough understanding of the anhydrous ammonia refrigeration cycle, thermodynamics, and system components
- Ability to read and interpret P&IDs, mechanical drawings, equipment manuals, and TCEQ permit documents
- Proficiency with CMMS (Computerized Maintenance Management Systems) and digital log-keeping
- Strong written and verbal communication for operator logs, TCEQ PBR recordkeeping, and incident reporting
- Ability to work rotating shifts, weekends, holidays, and on-call as required
- Physical ability to wear full PPE including SCBA, Level B chemical suit, and perform confined space entry
- General Duties & Responsibilities
- Operate, monitor, and control all ammonia refrigeration equipment including compressors, condensers, evaporators, pressure vessels, accumulators, pumps, and auxiliary systems
- Maintain system pressures, temperatures, and refrigerant charge within design specifications
- Monitor and respond to system alarms, abnormal readings, and emergency conditions at all hours
- Maintain accurate operator logs and inspection records compliant with OSHA PSM (29 CFR 1910.119), EPA RMP (40 CFR Part 68), and TCEQ 30 TAC §106.8 rolling 12-month recordkeeping requirements
- Maintain on-site TCEQ Permit by Rule (PBR) compliance records under 30 TAC §106.373 and/or §106.477 and make available for immediate inspection upon TCEQ request
- Adhere to PSM/RMP Program Management of Change (MOC) procedures for any system modifications
- Coordinate with contractors and vendors; verify contractor personnel hold required TDLR licenses or qualify under the industrial exemption
- Participate in emergency response planning, drills, and incident investigation
- Maintain OSHA 300/300A logs as required under 29 CFR 1904 (federal recordkeeping applies in Texas)
- Support all EHS programs including Hazard Communication (29 CFR 1910.1200 HazCom), LOTO (1910.147), confined space (1910.146), and hot work permitting
Promptly report any ammonia releases to the TCEQ as required under Texas Health and Safety Code Chapter 382 and TCEQ emergency notification rules; notify the National Response Center (NRC) for releases above RQ (100 lbs NH3) as required under CERCLAComplete all required training and maintain current certifications
Daily Inspection & Maintenance DutiesRecord all compressor suction/discharge pressures, temperatures, oil levels, and amp draws in the operator log
Inspect compressors for unusual vibration, noise, leaks, or overheating; check crankcase heaters
Verify condenser fan/pump operation; inspect evaporative condenser basin water level and chemical treatment
Check high-side and low-side vessel liquid levels (receivers, accumulators, intercoolers)
Inspect all safety relief valve (PRV) discharge piping for frost, moisture, or signs of weeping
Test operation of oil separators and oil pots; drain oil as needed
Inspect all visible ammonia piping, fittings, and valves for frost, ice, or visible leaks
Verify all ammonia gas detection/alarm systems are operational; confirm sensor readings are within calibration range
Check all automated controls, setpoints, and HMI/SCADA system for active faults or alarms
Perform portable gas detector sweep of engine room at start of each shift
Verify all PPE (SCBA, gas masks, chemical suits, gloves, face shields) is staged, accessible, and serviceable
Document all readings, observations, and corrective actions in the daily operator log; retain for TCEQ/OSHA compliance
Distribution Center Maintenance (Daily)
Inspect refrigerated dock doors, dock levelers, and dock seals for air infiltration or damage
Walk all refrigerated spaces; verify temperature setpoints are maintained in each zone; document readings
Check walk-in cooler/freezer temperatures and defrost cycle operation
Inspect unit coolers (evaporator coils) for ice buildup, proper drainage, and fan operation
Confirm operation of door heaters, anti-sweat heaters, and floor heating systems
Inspect and clear floor drains in refrigerated areas to prevent blockage and ice formation
Review prior shift logs for outstanding work orders, alarms, or deferred maintenance items
Communicate with warehouse supervision regarding temperature or equipment concerns affecting product integrity
Weekly Inspection & Maintenance DutiesTest operation of all high-pressure and low-pressure cutouts on each compressor; document results
Inspect and exercise all manual shut-off valves; lubricate valve stems as required
Inspect compressor coupling alignment and belt tensions; check for unusual wear patterns
Lubricate compressor shaft seals, bearings, and manufacturer-specified lubrication points
Inspect and record condenser coil cleanliness; water-wash or brush-clean fouled sections
Check cooling tower / evaporative condenser water treatment chemistry; add chemicals as required
Verify proper operation of all solenoid valves, check valves, and thermostatic/electronic expansion valves
Test battery backup and UPS systems for control panels
Inspect all electrical panels, junction boxes, and motor starters for overheating or damage
Perform calibration check on ammonia detector sensors; document readings; flag out-of-tolerance sensors
