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Automation Risk Analysis

Will “Process Control Operator” be Automated?

Historical Context: Oxford Study (2013)

Ranked #487 of 702. Estimated risk: 85.0%

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AI Exposure Risk

51%

“Process Control Operator” will maybe be replaced by AI.

Based on the cognitive demands, communication requirements, and logical reasoning intrinsic to this occupation according to O*NET data, we project a 51% probability of disruption by generative AI and Large Language Models.

Automation & Robot Risk

59%

“Process Control Operator” will maybe be replaced by robots.

Evaluating the physical dexterity, repetitive motion tasks, and manual labor associated with this role, our analysis indicates a 59% likelihood of substitution by advanced robotics systems.

Personal & Financial Insights

Every occupation has a unique profile. For Chemical Plant and System Operators, the Bureau of Labor Statistics and O*NET classify the day-to-day work broadly as: Control or operate entire chemical processes or system of machines.

Avg. Annual Salary $76,290
Avg. Hourly Wage $36.68
Available Jobs (US) 17,840
Job Title & Hierarchy Code (SOC) Chemical Plant and System Operators #51-8091
Wage vs. National Median
ℹ️

Data is based on the reference occupation: “Chemical Plant and System Operators”

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Core Skills & Abilities

  • Record operating data, such as process conditions, test results, or instrument readings.

  • Draw samples of products and conduct quality control tests to monitor processing and to ensure that standards are met.

  • Repair or replace damaged equipment.

  • Move control settings to make necessary adjustments on equipment units affecting speeds of chemical reactions, quality, or yields.

  • Interpret chemical reactions visible through sight glasses or on television monitors and review laboratory test reports for process adjustments.

  • Supervise the cleaning of towers, strainers, or spray tips.

  • Defrost frozen valves, using steam hoses.

  • Control or operate chemical processes or systems of machines, using panelboards, control boards, or semi-automatic equipment.

  • Confer with technical and supervisory personnel to report or resolve conditions affecting safety, efficiency, or product quality.

  • Turn valves to regulate flow of products or byproducts through agitator tanks, storage drums, or neutralizer tanks.

  • Patrol work areas to ensure that solutions in tanks or troughs are not in danger of overflowing.

  • Start pumps to wash and rinse reactor vessels, to exhaust gases or vapors, to regulate the flow of oil, steam, air, or perfume to towers, or to add products to converter or blending vessels.

  • Notify maintenance, stationary engineering, or other auxiliary personnel to correct equipment malfunctions or to adjust power, steam, water, or air supplies.

  • Gauge tank levels, using calibrated rods.

  • Regulate or shut down equipment during emergency situations, as directed by supervisory personnel.

  • Monitor recording instruments, flowmeters, panel lights, or other indicators and listen for warning signals to verify conformity of process conditions.

  • Inspect operating units, such as towers, soap-spray storage tanks, scrubbers, collectors, or driers to ensure that all are functioning and to maintain maximum efficiency.

  • Direct workers engaged in operating machinery that regulates the flow of materials and products.

  • Calculate material requirements or yields according to formulas.

Technologies & Software

  • Mistral (Mistral AI)
  • Llama (Meta)
  • Coordinated incident management system CIMS software
  • Microsoft Excel
  • Rockwell Automation AI
  • ChatGPT (OpenAI)
  • Kimi (Moonshot AI)
  • Microsoft Office software
  • Interlock shutdown systems
  • Sight Machine AI
  • Gemini (Google)
  • Grok (xAI)
  • Siemens Industrial AI
  • ABB AI Robotics
  • Claude (Anthropic)
  • Distributed control system DCS
  • Alarm management system software
  • DeepSeek
  • Nova (Amazon)
  • Cognex Vision AI
  • Qwen (Alibaba)
  • Microsoft Word
  • Chemical reactor vessels
  • Boilers
  • Neutralizer tanks
  • Control boards
  • Barometers
  • Cooling towers
  • Desktop computers
  • Wet scrubbers
  • Panel lights
  • Silencers
  • Calibrated rods
  • Personal protective equipment
  • Fire extinguishers
  • Reciprocating pumps
  • Pressure gauges
  • Collectors
  • Heating vessels
  • Conveyor feeders
  • Centrifugal compressors
  • Screw conveyors
  • Bourdon tubes
  • Reciprocating compressors
  • Panelboards
  • Effluent treatment systems
  • Air conditioning systems
  • Belt conveyors
  • Industrial liquid flowmeters
  • Rotary pumps
  • Hydraulic accumulators
  • Capacitance probes
  • Steam turbines
  • Mixing tanks
  • Radiographic detecting instruments
  • Refrigeration systems
  • Axial flow fans
  • Blending vessels
  • Thermocouple temperature probes
  • Gas analyzers
  • Storage drums
  • Agitator tanks
  • Converter vessels
  • Tensometers
  • Viscometers
  • Display screens
  • Distillation columns
  • Centrifugal fans
  • Positive displacement pumps
  • Manometers
  • Industrial dryers
  • Chain conveyors
  • Soap-spray storage tanks
  • Recording calorimeters
  • Steam hoses
  • Digital surface thermometers
  • Centrifugal pumps
  • Industrial fans
  • Humidifiers
  • Bucket elevators
  • Thermocouples
  • Hoppers