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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

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

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

  • Gauge tank levels, using calibrated rods.

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

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

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

  • Repair or replace damaged equipment.

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

  • 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.

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

  • 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.

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

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

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

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

  • Defrost frozen valves, using steam hoses.

  • Calculate material requirements or yields according to formulas.

Technologies & Software

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