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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

  • Defrost frozen valves, using steam hoses.

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

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

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

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

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

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

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

  • 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.

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

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

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

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

  • Gauge tank levels, using calibrated rods.

  • Repair or replace damaged equipment.

  • 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.

  • Calculate material requirements or yields according to formulas.

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

Technologies & Software

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