Process Safety Management Audits for Compliance and Continuous Safety Improvement

This workshop-style course provides a deep dive into the audit process for OSHA’s PSM standard, including scoping, data collection, interviewing, and reporting. Participants will explore real-world audit techniques, review key regulatory elements (1910.119), and practice mock interviews and audit meetings. By the end of the course, attendees will be prepared to lead audits that not only meet compliance requirements but also improve system reliability and safety performance.

View course details

Who Should Attend?

PSM coordinators and safety managers responsible for regulatory compliance.
Refrigeration operators, mechanics, and supervisors involved in system safety.
Audit team members and consultants seeking to enhance their audit effectiveness and technical understanding.

What You Will Learn

Conduct effective PSM audits using structured techniques for scoping, data collection, and reporting.
Evaluate compliance with OSHA 1910.119 standards and identify opportunities for system improvement.
Develop and apply interview strategies to gather meaningful insights during audits.

Course Details: RA00381-E029

Course Outline

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

Course Schedule

Location and Lodging

Course Location

Pyle Center

702 Langdon Street
Madison, WI 53706

Map

608-262-1122

866-301-1753

Lodging

Madison Concourse Hotel and Governor's Club

One West Dayton Street
Madison, WI 53703

Map

Room: rates start at $160

Accommodations include: Complimentary WiFi, Local/Airport Shuttle, Pool, and Fitness Center.

DoubleTree by Hilton Madison Downtown

525 West Johnson Street
Madison, WI 53703

Map

Accommodations include: Enjoy complimentary business center, WiFi and Local/Airport Shuttle. Each room has a refrigerator, microwave, 42-inch HDTV, and executive desk. Parking available $15/night.

Online Reservations

800-222-8733

608-251-5511

Fluno Center

601 University Avenue
Madison, WI 53706

Map

Accommodations include: Your stay includes hot breakfast buffet, fitness center, business center, convenient on-site parking. Guest rooms are complete with Keurig coffee maker, refrigerator, complimentary high-speed Internet, and 40-inch, flat screen, high-def TVs.

Online Reservations

877-773-5866

608-441-7117

More Madison Lodging Options

Course Notes

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 and Program Director

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

Additional Information

Total Credits:

CEU 2,

PDH 20,

Applies to this Certificate:

Process Safety Management Professional,

Course Administration

Fee Information

Fee covers morning and afternoon breaks, scheduled lunches and course materials

Discounts

Industrial Refrigeration Consortium (IRC) members receive $200 off the registration fee per person.

Payment Options

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 registration@cerc.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 registration@cerc.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.

Cancellation Policy

If you cannot attend, please notify us by no later than one week before your course begins, and we will refund your fee. Because this course has limited enrollment, cancellation received after this date and no-shows are subject to the full course fee. You may enroll a substitute at any time before the course starts.

Create a custom learning experience

We can deliver this course as an on-site learning experience tailored to your organization’s specific training needs.

"Instructors' knowledge and experience make the course very useful."
—Tom Boman, Amy's Kitchen, Inc.
"Thank you for making auditing fun and lively."
—Marie Joachim, General Mills Inc.
"I am leaving with a better understanding of PSM and how audits are conducted. I am also leaving with more knowledge of how to better prepare for an audit."
—Taylor Burtt, McCain Foods

Course Details: RA00381-E037

Course Outline

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

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

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

Course Schedule

Location and Lodging

Course Location

Pyle Center

702 Langdon Street
Madison, WI 53706

Map

608-262-1122

866-301-1753

Lodging

Madison Concourse Hotel and Governor's Club

One West Dayton Street
Madison, WI 53703

Map

Room: rates start at $160

Accommodations include: Complimentary WiFi, Local/Airport Shuttle, Pool, and Fitness Center.

DoubleTree by Hilton Madison Downtown

525 West Johnson Street
Madison, WI 53703

Fluno Center

601 University Avenue
Madison, WI 53706

More Madison Lodging Options

Course Notes

Instructors and Program Director

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

Additional Information

Total Credits:

CEU 2,

PDH 20,

Applies to this Certificate:

Process Safety Management Professional,

Course Administration

Fee Information

Fee covers morning and afternoon breaks, scheduled lunches and course materials

Discounts

Industrial Refrigeration Consortium (IRC) members receive $200 off the registration fee per person. Member affiliation will be verified.

Payment Options

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 registration@cerc.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 registration@cerc.wisc.edu for details and instructions.

Event Cancellation

Cancellation Policy

If you cannot attend, please notify us by no later than one week before your course begins, and we will refund your fee. Because this course has limited enrollment, cancellation received after this date and no-shows are subject to the full course fee. You may enroll a substitute at any time before the course starts.

Create a custom learning experience

We can deliver this course as an on-site learning experience tailored to your organization’s specific training needs.

"Instructors' knowledge and experience make the course very useful."
—Tom Boman, Amy's Kitchen, Inc.
"Thank you for making auditing fun and lively."
—Marie Joachim, General Mills Inc.
"I am leaving with a better understanding of PSM and how audits are conducted. I am also leaving with more knowledge of how to better prepare for an audit."
—Taylor Burtt, McCain Foods

Process Safety Management Audits for Compliance and Continuous Safety Improvement

2027 and later

Who Should Attend?

What You Will Learn

Course Details: RA00381-E029

Course Outline

Course Schedule

Location and Lodging

Course Notes

Instructors and Program Director

Additional Information

Course Administration

Fee Information

Discounts

Payment Options

Pay by Credit Card

Enroll online and pay by credit card.

Enroll over the phone and pay by credit card.

Pay by Check

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

Pay by Purchase Order

Military

Event Cancellation

Cancellation Policy

Stay Connected

Course Details: RA00381-E037

Course Outline

Course Schedule

Location and Lodging

Course Notes

Instructors and Program Director

Additional Information

Course Administration

Fee Information

Discounts

Payment Options

Pay by Credit Card

Enroll online and pay by credit card.

Enroll over the phone and pay by credit card.

Pay by Check

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

Pay by Purchase Order

Military

Event Cancellation

Cancellation Policy

Stay Connected

Related Courses

Process Hazard Analysis Emphasizing Ammonia Refrigeration Systems

Design of Ammonia Refrigeration Systems for Peak Performance and Efficiency

Introduction to Ammonia Refrigeration Systems

Principles and Practices of Mechanical Integrity for Industrial Refrigeration Systems

Intermediate Ammonia Refrigeration Systems

Past Courses

Process Safety Management Audits for Compliance and Continuous Safety Improvement

Process Safety Management Audits for Compliance and Continuous Safety Improvement