Chemical Plant Operators

Career summary

Workers in these occupations may also be called chemical plant and system operators.

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Chemical plant operators monitor all steps of the chemical production process. They supervise chemical equipment operators.

Plant operators make sure chemicals are mixed properly. Using industry standards, they take samples to inspect the quality of chemicals being produced. If there is a problem, chemical plant operators determine what is wrong and fix it.

Chemical plant operators inspect equipment for safety problems, leaks, or wear. They discuss repairs with maintenance staff. They tell engineers if the amount of air, power, or steam needs to be adjusted during production. They gauge tank levels using special tools. They adjust the flow of chemicals if tanks get close to overflowing. If there is an emergency, plant operators shut down the machines.

Once a production cycle is complete, operators start pumps to clean the tanks, empty gases, and prepare for the next production cycle.

Chemical plant operators use several tools in their job. For example, they use measuring rods to check tank levels and steam hoses to defrost frozen valves. They use sight glasses to observe if chemicals are reacting correctly.

Operators record the amount of ingredients used and the amount of chemicals produced. They keep a record of their findings when they take samples.

Related careers

This career is part of the Manufacturing cluster of careers.

Related careers include:

• Chemical Engineers
• Chemical Equipment Operators
• Gas and Oil Plant Operators
• General and Operations Managers
• Hazardous Material Workers
• Power Plant Operators
• Pump Operators
• Tank Car, Truck, and Ship Loaders
• Water Treatment Plant Operators

Job duties

Task list

The following list of tasks is specific to chemical plant operators.

• Take samples of products and test them for quality.
• Monitor instruments, meters, and lights, to verify processing.
• Compare samples against standards.
• Talk to engineers, scientists, or supervisors to report or improve safety, production time, and quality.
• Inspect equipment for possible or actual hazards, wear, or leaks. Look for damage that would require machines to be turned off for repair.
• Discuss maintenance with repairers.
• Alert engineers who operate power or ventilation systems to change the amount of air, power, or steam.
• Check chemical tank levels using measuring rods.
• Patrol work area to look at chemical levels in overflow tanks.
• Defrost frozen valves using steam hose.
• Record test data, the amount of chemicals used, and the amount of product produced.
• Follow supervisors' directions to shut down equipment in emergencies.
• Interpret chemical reactions using sight glasses.
• Check panel lights to be sure they are working correctly.
• Adjust settings on equipment to change the speed of the chemical process.
• Start pumps to clean tanks, empty gases and vapors, and mix product with water.
• Turn valves to control flow of product through tanks and storage drums.
• May direct workers who operate machinery.

Common work activities

Chemical plant operators perform the following tasks. These tasks are common to many careers.

• Get information needed to do the job
• Monitor events, materials, and surroundings
• Identify objects, actions, and events
• Control machines and processes
• Teach others
• Evaluate information against standards
• Inspect equipment, structures, or materials
• Make decisions and solve problems
• Communicate with supervisors, peers, or subordinates
• Use computers
• Document and record information
• Perform activities that use the whole body
• Handle and move objects
• Explain the meaning of information to others
• Update and use job-related knowledge
• Process information
• Repair and maintain mechanical equipment
• Analyze data or information

Work requirements

Working conditions

In a typical work setting, chemical plant operators:

Interpersonal relationships

• Have a medium to high level of social contact.
• Communicate daily by telephone and in person. They also write e-mails, letters, and memos, but far less frequently.
• Often work as part of a team.
• Are greatly responsible for the health and safety of others.
• Are responsible for the work done by others.

Physical work conditions

• Always wear hardhats and safety goggles while touring the plant. When working with dangerous chemicals, body suits and breathing devices are required.
• Often work indoors. However, some parts of chemical plants may be exposed to the outside weather.
• Are regularly exposed to sounds and noise levels that are distracting or uncomfortable.
• Are sometimes exposed to hazardous conditions. The chance of injury is low, but if injured, the level of injury is moderate.
• Sometimes are exposed to hazardous chemicals, gases, or hot equipment or liquid.
• Are often exposed to very hot or very cold temperatures.
• Must occasionally work in high places.
• May occasionally work in a vehicle or equipment that is open.
• Sometimes share work space with others.
• Sometimes must get into awkward positions to reach cramped work spaces.

Work performance

• Must be sure that all details are completed accurately. Errors could cause serious safety problems in the plant or for other workers.
• Must keep pace with the speed of equipment or machinery.
• Often repeat the same physical or mental activities.
• Regularly make decisions that greatly impact coworkers and their employer.
• Make most, but not all, of their decisions without consulting a supervisor.
• Set some, but not all, of their daily tasks and goals without consulting a supervisor.
• Must meet weekly deadlines.

Hours/travel

• May work days, nights, or weekends.
• May work split shifts. For example, they might work from 6 a.m. to 10 a.m. and 3 p.m. to 7 p.m., with time off in between.
• May work more than 40 hours a week.
• Usually work a set schedule.

Physical demands

Chemical plant operators frequently:

• Use their hands to handle, control, or feel objects, tools, or controls.
• Stand for long periods of time.
• Walk or run for long periods of time.

It is important for chemical plant operators to be able to:

• See details of objects that are less than a few feet away.
• See details of objects that are more than a few feet away.
• Make quick, precise adjustments to machine controls.
• Hold the arm and hand in one position or hold the hand steady while moving the arm.
• Hear sounds and recognize the difference between them.
• Focus on one source of sound and ignore others.
• React quickly using hands, fingers, or feet.
• Use one or two hands to grasp, move, or assemble objects.
• Understand the speech of another person.
• Speak clearly so listeners can understand.
• See differences between colors, shades, and brightness.
• Use fingers to grasp, move, or assemble very small objects.

It is not as important, but still necessary, for chemical plant operators to be able to:

• Move two or more limbs together (for example, two arms, two legs, or one leg and one arm) while remaining in place.
• Adjust body movements or equipment controls to keep pace with speed changes of moving objects.
• Use stomach and lower back muscles to support the body for long periods without getting tired.
• Make fast, repeated movements of fingers, hands, and wrists.
• Use muscles to lift, push, pull, or carry heavy objects.
• Bend, stretch, twist, or reach out.
• Determine the distance between objects.
• Keep or regain the body's balance or stay upright when in an unstable position.
• Be physically active for long periods without getting tired or out of breath.
• Choose quickly and correctly among various movements when responding to different signals.
• Coordinate movement of several parts of the body, such as arms and legs, while the body is moving.
• See objects in very bright or glaring light.
• Use muscles for extended periods without getting tired.

Skills and abilities

Chemical plant operators need to:

Communicate

• Speak clearly so listeners can understand.
• Understand spoken information.
• Listen to others and ask questions.
• Read and understand work-related materials.
• Understand written information.
• Write clearly so other people can understand.

Reason and problem solve

• Notice when something is wrong or is likely to go wrong.
• Concentrate and not be distracted while performing a task.
• Use reasoning to discover answers to problems.
• Follow guidelines to arrange objects or actions in a certain order.
• Analyze ideas and use logic to determine their strengths and weaknesses.
• Recognize the nature of a problem.
• Understand new information or materials by studying and working with them.
• Judge the costs and benefits of a possible action.
• Combine several pieces of information and draw conclusions.
• Develop rules that group items in various ways.

Manage oneself, people, time, and things

• Check how well one is learning or doing something.
• Manage the time of self and others.

Work with things

• Watch gauges, dials, and output to make sure a machine is working properly.
• Operate and control equipment.
• Inspect and evaluate the quality of products.

Perceive and visualize

• Quickly and accurately compare letters, numbers, objects, pictures, or patterns.
• Identify a pattern (a figure, object, word, or sound) that is hidden in distracting material.

Education and training

Educational programs

The programs of study listed below will help you prepare for the occupation or career cluster you are exploring.

Programs of study directly related to this occupation

• Chemical Technology
• Process Technology

Other programs of study to consider

• Industrial Mechanics
• Water and Wastewater Treatment Technology

Training

To work as a chemical plant operator, you typically need to:

• have a high school diploma or equivalent; and
• complete moderate-term, on-the-job training.

Education after high school

Some chemical plant operators have an associate degree. A common area of study is chemical technology. This program teaches you the principles of chemistry, computer applications, and laboratory research methods.

On-the-job training

Most chemical plant operators learn their skills on the job. As a new worker, you begin by helping other operators. As you gain experience, you learn to handle chemicals. You also learn safety procedures. After training, another worker may supervise your work. Training generally lasts up to one year.

Helpful high school courses

You should take a general high school curriculum that meets the state's graduation requirements. You will be required to take both math and science classes to graduate. You should consider taking Algebra and Geometry as your math courses and Chemistry and Physics as your science courses.

Helpful electives to take in high school that prepare you for this career include:

• Computer Fundamentals
• Equipment Maintenance and Repair
• Safety and First Aid
• Technology Systems

The courses listed above are meant to help you create your high school plan. If you have not already done so, talk to a school counselor or parent about the courses you are considering taking.

You should also check with a teacher or counselor to see if work-based learning opportunities are available in your school and community. These might include field trips, job shadowing, internships, and actual work experience. The goal of these activities is to help you connect your school experiences with real-life work.

Join some groups, try some hobbies, or volunteer with an organization that interests you. By participating in activities you can have fun, make new friends, and learn about yourself. Maybe one of them will help direct you to a future career. Here are examples of activities and groups that may be available in your high school or community.

Things to know

Employers look for workers who have a high school diploma or equivalent. They may also look for workers who have experience in working at chemical plants. Employers may prefer applicants who have taken chemistry classes and have a background in engine repair. Employers look for operators who have good communication skills and can discuss problems with coworkers.

Costs to workers

Union workers must pay an initiation fee and monthly dues.

Job listings

Listed below are links to job categories from the National Labor Exchange that relate to this career. Once you get a list of jobs, you can view information about individual jobs and find out how to apply. If your job search finds too many openings, or if you wish to search for jobs outside of Washington, you will need to refine your search.

• Chemical Plant and System Operators 

To get a listing of current jobs from the WorkSource system, go to the WorkSource website .

Wages

Since chemical production is ongoing, operators work around the clock. Those who work nights and weekends usually receive higher pay. Wages vary by the size of the plant. Wages also vary depending on the products workers make. For example, those who produce chemicals earn more than those who produce soaps or cosmetics. Wages also vary by the operator's level of experience and training. Those with more experience or formal training earn more than those with little experience or training.

Chemical plant operators who work full time usually receive benefits. These may include health insurance, paid vacation, and a retirement plan. Some employers pay for workers to attend training sessions.

Employment and outlook

Washington outlook

The table below provides information about the number of workers in this career in various regions. It also provides information about the expected growth rate and future job openings.

National employment

Many chemical companies are located in major manufacturing areas, such as the Great Lakes region. Because chemical production uses water, and because many products are shipped to other countries, chemical plants tend to be near major shipping ports.

Major employers:

• Chemical manufacturing companies
• Plastic manufacturing companies
• Agricultural chemical manufacturing companies
• Drug manufacturing companies

National outlook

Demand is decreasing for this occupation. First, automation is reducing the need for chemical plant operators. Second, labor is less expensive in other countries, so fewer companies are buying chemicals from American chemical plants. Third, environmental health and safety concerns may prevent new chemical processing plants from opening. These factors may also cause some plants to close.

Jobs will be available in this occupation as current workers retire or leave for other reasons. There is competition for these jobs because of the good pay and benefits.

Other resources

American Chemistry Council 
700 Second Street NE
Washington, DC 20002
202.249.7000

Washington Business Week 
PO Box 1170
Renton, WA 98057
253.237.3545

References

Career cluster

• Manufacturing

Career path

• Realistic (Technical)

O*Net  occupation

• Chemical Plant and System Operators (51-8091.00) 

O*Net job zone 

• Job Zone 2 - Some preparation needed. Some previous work-related skill, knowledge, or experience may be helpful in these occupations, but usually is not needed.

DOT occupations

• Ammonia-still Operator (559.382-010) 
• Checker (559.165-010) 
• Chief Operator (558.260-010) 
• Naphtha-washing-system Operator (559.382-038) 
• Wash Operator (559.662-014) 

Holland occupational cluster

• Realistic/Conventional/Investigative

COPSystem

• Technology Skilled