This course explores the essentials of conducting effective PHAs for ammonia refrigerated facilities, including regulatory requirements under OSHA's Process Safety Management (PSM) standard and EPA's Risk Management Plan (RMP) rule. Attendees will receive updates on how the recent SCCAP rule changes to RMP have impacted PHA requirements along with strategies to ensure compliance. In break-out group exercises, you will apply What-if/Checklist and HAZOP methodologies as part of a mock PHA for two different ammonia refrigeration systems. This course is your opportunity to improve your ability to identify hazards, evaluate risks, and implement effective recommendations to ensure ammonia refrigeration systems safety.

• Understand PHA regulatory requirements under OSHA’s PSM standard and EPA’s RMP rule
• Develop and apply PHA methodologies, including What-if/Checklist and HAZOP, to identify and evaluate hazards effectively
• Enhance ammonia refrigeration system safety through actionable recommendations based on thorough hazard analyses

• PSM coordinators and safety/environmental professionals responsible for managing PSM programs and organizing/leading PHAs
• Refrigeration operators and design engineers working with ammonia systems and participating in PHAs
• Consulting engineers and process safety professionals who will lead PHAs

Participants can also earn a digital badge, showcasing their mastery of course material and demonstrating their professional growth. These micro-credentials are awarded upon successful completion of an online final quiz, providing tangible evidence of your achievement and commitment to excellence in process safety. Take this opportunity to bolster your skills and advance your career. Click here for information on digital badges.

Day 1

Welcome

Introduction to Process Hazard Analysis

• Hazards – what they are and how to identify them
• PHA regulatory requirements
• When and why should you conduct hazard evaluations or analyses?
• OSHA interpretations on PHAs

Preparing for a PHA

• How to define PHA objectives and scope
• Staffing
• Information requirements
• Strategies to effectively engage all PHA participants

Critical Factors to Include in PHAs

• Human factors
• Facility siting
• Failure of engineering and administrative controls (safeguards)
• How to account for all operating scenarios

Workshop (Human Factors-Related)

P&IDs -Their Role in the PHA Process

• Purpose of P&IDs
• Characteristics of effective P&IDs
• Role of P&IDs in the PHA process

Management of Change (MOC)

• How changes impact the process hazard analysis
• “Change” vs. “replacement in-kind”
• Types of changes that should trigger a PHA
• OSHA interpretations on MOCs that lead to PHAs

Day 2

Overview of PHA Methodologies

• What-if/Checklist
• Hazard and Operability Study/Analysis (HAZOP)
• Failure Mode and Effects Analysis (FMEA)
• Fault tree analysis
• Advantages, disadvantages, and limitations of each methodology
• Importance of matching the PHA methodology to the complexity of the process

How to Conduct a PHA Using the What-if/Checklist Methodology

• Identify PHA objectives, scope, and subsystems
• Gather required information as input to the process
• Develop and modify the What-if/Checklist
• Rank risks and how risk impacts requirements for recommendations
• Document the PHA process and findings
• Pitfalls
• Preview of What-if/Checklist workshop

What-if/Checklist Workshop

Given appropriate preliminary documentation (P&IDs, photos, etc.), you will work in groups to define PHA objectives and subsystems for analysis, review given information, modify the What-if/Checklist, and complete a first-cut of a hazard evaluation list. Representatives from each group will present their PHA objective(s) and What-if/Checklist modifications.

Site Visit-Engine Room Walk-thru

Day 3

What-if/Checklist Workshop – (Continues)
Each group conducts a mock PHA using their What-if/Checklist.

What-if/Checklist Workshop Closeout

Roundtable discussion of site visit and PHA using the What-if/Checklist methodology

PHA Revalidation

• Revalidation requirements
• Planning for revalidation
• Redo, update, revise and revalidate-what’s the difference?
• How to conduct and document the PHA revalidation

Action Required Following a PHA

• Determine actionable recommendations
• Resolution of PHA action items
• Prioritization
• Management response
• Communication of findings

PHA Process Quality Improvement

• Post-mortem evaluation of a PHA session
• Strategies to achieve PHA process improvement

"Your courses are well thought out and planned to provide everything I expected. All speakers were very helpful and professional. Thank you."

"I came in clueless and I feel comfortable with the knowledge gained."

"Good class. I learned all I expected to."

"Great enlightening experience on PHAs, HAZOP, etc. Very informative material and an excellent, resourceful staff. Thanks."

Douglas Reindl

Douglas Reindl, PhD, PE is a professor in the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin–Madison. He brings extensive expertise in mechanical systems, with a particular focus on industrial ammonia refrigeration. As the founding director of the Industrial Refrigeration Consortium, Dr. Reindl is dedicated to advancing the safety, efficiency, and reliability of refrigeration infrastructure. He holds a BS in Mechanical Engineering Technology from the Milwaukee School of Engineering, and both MS and PhD degrees in Mechanical Engineering from UW–Madison. A registered professional engineer in Wisconsin, Dr. Reindl is widely recognized for his leadership in refrigeration education and applied research.

Marc Claas

Marc Claas is an Associate Researcher with the Industrial Refrigeration Consortium, specializing in industrial refrigeration since 2009. He focuses on system maintenance, safe operation, troubleshooting, and regulatory compliance, with a growing interest in emerging cooling technologies. Marc has led online operator training programs and brings extensive field experience in Process Safety Management (PSM), including audits and Process Hazard Analyses (PHAs). He also investigates energy efficiency and operational improvements in refrigeration systems. Marc holds a B.S. in Mechanical Engineering from UW-Platteville and an M.S. in Mechanical Engineering with a focus on Thermal Sciences from UW-Madison. He is an active member of the International Institute of Ammonia Refrigeration.

Todd Jekel

Todd Jekel, PhD, PE is the Assistant Director of the Industrial Refrigeration Consortium (IRC) at the University of Wisconsin–Madison, where he leads applied research and technical outreach in industrial refrigeration. His work focuses on system and component modeling, refrigeration load and energy calculations, accumulator design, and safety relief vent systems. Dr. Jekel has contributed to the development and instruction of several web-based and in-person courses for refrigeration professionals, covering topics such as ammonia refrigeration, process safety, and energy efficiency. He holds degrees from Calvin College and the University of Wisconsin–Madison. In addition to his academic and research roles, he is an active member of ASHRAE and the International Institute of Ammonia Refrigeration (IIAR), serving on multiple technical committees. Dr. Jekel is recognized for his expertise in vessel design, oil separation, and dehumidification strategies for cold storage facilities.