Covered Process ConsultingPSM / RMP SERVICES
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Ammonia Refrigeration PSM & RMP Consulting Services

Your covered process, covered.

At Covered Process Consulting, we understand that process safety is more than documentation. With a background in industrial ammonia refrigeration operations, mechanical service, and regulatory compliance, we help facilities develop practical, effective PSM and RMP programs that reflect their actual equipment and operations.

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Cold StorageWarehousing and distribution centers
Food & DairyProcessing and production plants
BeverageBreweries, bottling and process cooling
PSM FirmsField and subcontract support

Services

What we do

Support for every part of a covered ammonia process, from a single annual inspection to a full program build-out.

Audits & Analysis

Compliance

Independent reviews that show where your program stands and what to fix before an inspector finds it.

  • PSM / RMP compliance audits
  • IIAR 9 gap analysis for existing systems
  • Process Hazard Analysis facilitation and PHA audits
  • RAGAGEP reviews
IIAR 6

Mechanical Integrity

Hands-on inspections by someone who has serviced equipment in the field, with clear findings and recommended actions.

  • Annual mechanical integrity inspections
  • 5-year mechanical integrity inspections
Programs & Documentation

PSM & RMP Programs

Written programs and process safety information that match how your plant actually runs.

  • PSM consulting and program development
  • RMP consulting and Offsite Consequence Analysis
  • Initial RMP / OCA submissions
  • Standard Operating Procedure creation and adjustment for compliance
  • Emergency planning and response
  • Valve tagging
  • Pipe labeling
  • PSM / RMP computerized program support
Training

Operator & Safety Training

Practical training from a RETA-certified operator who has trained plant crews across multiple facilities.

  • Operator training
  • Refresher training
  • HAZWOPER training (8-hour operations level and refresher)
Engineering

Engineering Support

Drawings and calculations that keep your process safety information accurate and current.

  • P&ID development and editing services
  • Maximum intended inventory calculations
  • MEB development and adjustment
  • Relief system analysis
  • Ventilation assessment

About

Built on the plant floor

We founded Covered Process Consulting after a decade of running and servicing ammonia refrigeration systems. Before consulting, we managed refrigeration operations and PSM compliance across multiple cold storage and production facilities, where we developed SOPs, led PHAs, ran mechanical integrity and management of change programs, oversaw contractors, and trained operators.

That background shapes how CPC works. Recommendations are practical, inspections are thorough, and the paperwork matches what is actually in your facility.

Certifications

  • Certified Industrial Refrigeration Operator (CIRO)RETA
  • Process Safety Management Professional (PSMP)University of Wisconsin–Madison
  • Ammonia Operator 1, 2 & 3
  • OSHA 24-Hour HAZWOPERWith incident command experience
RETA Certified Industrial Refrigeration Operator (CIRO) seal UW–Madison Process Safety Management Professional Certificate badge

OSHA 29 CFR 1910.119

Every element of your PSM program

We can support any of the fourteen elements, whether you need one element fixed or the whole program reviewed. Select an element to read its requirements in the OSHA standard.

(c)Employee Participation (d)Process Safety Information (e)Process Hazard Analysis (f)Operating Procedures (g)Training (h)Contractors (i)Pre-Startup Safety Review (j)Mechanical Integrity (k)Hot Work Permits (l)Management of Change (m)Incident Investigation (n)Emergency Planning & Response (o)Compliance Audits (p)Trade Secrets

EPA 40 CFR Part 68

Every element of your Risk Management Program

Most ammonia refrigeration facilities above the 10,000-pound threshold are Program 3 processes under the RMP rule. We support each requirement, from the hazard assessment and offsite consequence analysis to your five-year RMP resubmission. Select an element to read its requirements in the regulation, or visit the EPA RMP program page.

§68.15Management System §68.20Hazard Assessment & OCA §68.65Process Safety Information §68.67Process Hazard Analysis §68.69Operating Procedures §68.71Training §68.73Mechanical Integrity §68.75Management of Change §68.77Pre-Startup Review §68.79Compliance Audits §68.81Incident Investigation §68.83Employee Participation §68.85Hot Work Permits §68.87Contractors §68.90Emergency Response §68.150RMP Submission & Updates

Below the threshold

General Duty Clause facility? We cover that too.

Systems that aren't subject to PSM or RMP still carry obligations under OSHA's General Duty Clause (Section 5(a)(1) of the OSH Act) and EPA's General Duty Clause (Clean Air Act Section 112(r)(1)).

We support General Duty Clause facilities the same way we support covered processes: hazard analyses, mechanical integrity inspections, operating procedures, training and emergency planning, all built to recognized and generally accepted good engineering practice, including IIAR 9.

Know your deadlines

Compliance calendar

The recurring requirements most ammonia facilities need to plan around. If one of these is coming due, we can help you get ahead of it.

FrequencyRequirementReference
AnnuallyMechanical integrity inspections of the refrigeration system and its associated componentsANSI/IIAR 6
AnnuallyCertify standard operating procedures as current and accurate1910.119(f)(3)
Every 3 yearsPSM compliance audit1910.119(o)(1)
Every 3 yearsRMP compliance audit40 CFR 68.79
Every 3 yearsOperator refresher training1910.119(g)(2)
Every 5 yearsPHA update and revalidation1910.119(e)(6)
Every 5 yearsRMP update and resubmission40 CFR 68.190
Every 5 years5-year mechanical integrity inspectionANSI/IIAR 6
Every 5 yearsIIAR 9 minimum safety criteria reviewANSI/IIAR 9

Refresher training is required at least every three years, and more often if needed.

Changes to your facility, personnel or processes, including anything handled through Management of Change, can alter these schedules. If you have questions about how a change affects your deadlines, send us a note through the request form.

For PSM consulting firms

Need an experienced hand for a PHA, a mechanical integrity audit or field data collection? CPC works as a subcontractor for other PSM firms and fits into your process.

We work directly with the industry's leading PSM software companies and can provide support on all of their platforms. That includes setting up programs, loading process safety information, and keeping mechanical integrity, management of change and compliance records current for your clients.

Are you a PSM software company that would like to be represented here? Please reach out through the contact section below.

We proudly support the R-717 Safety nonprofit organization.

Talk Partnership

Contact

Request a quote

Tell us about your facility and what you need. We'll follow up within one business day.

Phone 608-977-1592
Email ryan@coveredprocessconsultingllc.com
Service Area

Based in Stoughton, Wisconsin. Serving facilities throughout the Midwest and nationwide.