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

Registration Date/Time:
1/20/2027 7:30am Central Time

Event Dates/Times:

• 1/20/2027  8:00am - 5:00pm Central Time
• 1/21/2027  8:00am - 5:00pm Central Time
• 1/22/2027  8:00am - 2:00pm Central Time

This in-person course uses the Canvas learning management system to provide access to instructional materials, participation certificates, and course evaluations. A UW NetID is required to log in to Canvas.

Your registration confirmation email will include step-by-step instructions for setting up your NetID and accessing the Canvas course site. Please check your spam folder if you do not see your confirmation or UW communication emails from the "@wisc.edu" address.

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. The course can be taken individually. 

• Instructors

  Douglas Reindl

  PROFESSOR

  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.

  Todd Jekel

  Assistant Director

  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.

  Marc Claas

  Researcher

  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.

• Program Director

  Douglas Reindl

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.