Process Safety Management Audits for Compliance and Continuous Safety Improvement

Day 1

Welcome

Overview of Process Safety Management System Audits

• Audit vs. inspection
• Process safety audits vs. process safety management system audits
• PSM audit requirements
• What are the goals or objectives of an audit?

The Audit Process

• Scoping and staffing
• Data collection
• Reporting
• Quality assurance
• Third-party compliance audits—tips and traps

Auditing Techniques 

• Techniques for audit scoping based on risks, past incidents or past audit results
• Assessment of PSM management systems
• Data collection techniques including document reviews, interviews, field inspections, and verification
• Audit reports Audit Techniques Workshop – Fred Elder and Doug Reindl Working in two groups, attendees will be asked to consider their plant(s) and determine the following:
• Self-assessment of your current compliance audit approach?
• What are opportunities to improve your audits? How? For your next audit:
• How will you scope the audit?
• What data collection/gathering techniques will you use?
• In what format will you prepare the audit reports?

Auditing Approaches

The following series of presentations will review key points for each element of the PSM standard. We will emphasize facets of the program elements that have been identified as weaknesses from previous OSHA PSM compliance audits.

• 1910.119(c): Employee participation
• 1910.119(d): Process safety information Auditing Approaches (continued) – Fred Elder
• 1910.119(e): Process hazard analyses
• 1910.119(f): Operating procedures Assign Homework Review 1910.119, 1910.120(q), and 1910.38a

Day 2

Auditing Approaches (continued)

• 1910.119(g): Training

Auditing Approaches (continued)

• 1910.119(h): Contractors
• 1910.119(i): Pre-startup safety review
• 1910.119(j): Mechanical integrity
• 1910.119(k): Hot work

Overview of PSM Auditing Tools and Resources

Auditing Approaches (continued)

• 1910.119(l): Management of change
• 1910.119(m): Incident investigation
• 1910.119(n): Emergency planning and response

Interviews

• Purpose of interviewing
• Approaches for conducting effective interviews
• How to identify staff to interview
• Interviewing tips and traps

Day 3

Interview Scoping Workshop

Course participants will prepare interview forms to conduct interviews with a mock plant staff during this program segment.

Conducting Interviews

Course participants will conduct mock interviews. During the interviews, participants will observe and critique the interviewer based on their interaction with plant staff being interviewed. The exercise will focus on developing good interview habits and techniques. The exercise will also involve conducting

• mock PSM
• MP Audit Opening Meetings and PSM
• MP Audit Closing Meetings

• 1/14/2026  08:00am - 05:00pm
• 1/15/2026  08:00am - 05:00pm
• 1/16/2026  08:00am - 02:00pm

All times listed are Central Time Zone

This in-person course will have an online course site from which you will access the course materials, course evaluation, and participation certificate. Details on how to access the online course site will be sent with registration confirmation.

• Program Director

  Douglas Reindl

• Marc Claas

  Researcher

  Marc Claas is an Associate Researcher with the Industrial Refrigeration Consortium and has been involved in industrial refrigeration since 2009. His interests include refrigeration system maintenance requirements, criteria for safe system operation, troubleshooting systems for safe and efficient operation, regulatory compliance in refrigeration systems, and emerging cooling technologies. His teaching experience includes online operator training programs, and his field experience includes PSM related activities such as PSM audits and PHAs. He also has experience investigating energy efficiency and other operational opportunities. Claas holds a Bachelor’s degree in Mechanical Engineering from UW-Platteville and Master’s of Mechanical Engineering in Thermal Science from UW-Madison. He is an active member of the International Institute of Ammonia Refrigeration.

• Todd Jekel

  Assistant Director

  Todd Jekel, PhD, PE is the assistant director of the Industrial Refrigeration Consortium at the University of Wisconsin–Madison. Jekel has been actively conducting research on refrigeration systems including vessel design practices, oil separators, and analysis of dehumidification alternatives for cold storage warehouses. He holds degrees from Calvin College and the University of Wisconsin–Madison.

• Douglas Reindl

  Professor

  Douglas Reindl, PhD, PE is a professor at the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin-Madison. He has extensive experience in mechanical systems – including industrial ammonia refrigeration systems. As the founding director of the Industrial Refrigeration Consortium, he works extensively to improve the safety, efficiency, reliability, and productivity of ammonia refrigeration infrastructure. Dr. Reindl received his BS in mechanical engineering technology from the Milwaukee School of Engineering, MS in mechanical engineering from UW–Madison, and PhD in mechanical engineering from UW–Madison. He is a registered professional engineer in the State of Wisconsin.

If you are planning to attend an Interdisciplinary Professional Programs course, payment is required at the time of registration. Below are the payment options:

Pay by Credit Card

Enroll online and pay by credit card.

• Search for the course on the website and then click on the Enroll Now button from the course webpage.
• Enter all necessary course attendee information and payment information on the course enrollment page.
• You will receive an email to confirm successful enrollment and payment.

Enroll over the phone and pay by credit card.

• Call CERC Registrations at 608-262-2451.
• Provide the registrations representative with:
  • the course name, dates, and/or course number.
  • the necessary course attendee information and payment information.
• You will receive either a mailed document or an email to confirm successful enrollment payment.

Pay by Check

Mail in a completed registration form and check payable to UW Madison.

• Fill out a registration form (found either in the back of the course brochure you received in the mail or here).
• Prepare a check, made payable to UW Madison.
• Mail the registration form and check to: CERC Registrations 21 N Park St, Ste 7101 Madison, WI 53715
• You will receive either a mailed document or an email to confirm successful enrollment and payment.

Pay by Purchase Order

• Request Purchase Order information from interpro@union.wisc.edu
  • If a fee quote is needed, contact custserv@interpro.wisc.edu first
• You will receive an invoice from UW–Madison Business Services for payment, usually within 3–5 business days

Military

If using SF-182 form, please call our registration number at 608-262-2451 or email interpro@union.wisc.edu for details and instructions.

Event Cancellation

We reserve the right to cancel a course due to insufficient enrollment or unforeseen events. If we cancel a course, participants will be notified via email or phone and will be given the option for a full refund or to transfer their registration and any fees paid to another course. We are not responsible for non-refundable plane tickets, hotel reservations, and other travel related expenses. For enrollee Course Cancellation, refer to notes on course page.

If you cannot attend, please notify us no later than one week before your course begins, and we will refund your fee. Cancellations received after this date and no-shows are subject to a $150 administrative fee. You may enroll a substitute at any time before the course starts.

This course is part of the Process Safety Management Professional Certificate. Increase your knowledge and effectiveness at managing PSM/RMP programs for your ammonia refrigerated facility, while earning a recognized credential. Course can be taken individually as well.

Attendees participating in this course will be able to earn a digital badge as evidence of the knowledge they obtained during the course. Digital badges are micro-credentials that can be earned by successfully passing a final quiz administered online after completing the course. Click here for information on digital badges.