Process Operator/ Process Technician- A Day in the Life
Process Operator/ Process Technician- A Day In The Life
Process Operator in a Chemical Plant
Curious what the heck it means when someone says they are a Process Operator/Process Technician? Well, I’ve got the scoop!
My husband, Anthony, is an operator at a chemical plant and my first-hand source for this article.
Process operators have a reputation for making good money and working a lot of hours… and it’s true. Of course, “good money” is relative, but in Texas, the demand for process operators is high, and overtime is abundant.
Blue-collar
To put it simply, chemical plants convert raw materials into resources that manufacturers need to create many of the products we use daily, such as plastic goods and car parts, for example.
A refinery is a complicated complex covered in pipes, compressors, boilers, tanks, and other equipment. It looks like a maze of above-ground piping of all sizes, snaking around each other every which way.
Process Operator is a blue-collar job, working indoors and outdoors, rain or shine, day and night. It is not a traditional 9-5. Anthony works two weekends a month and some holidays, depending on how the schedule falls that year.
Day-to-Day Tasks
Imagine it’s 6 p.m, and Anthony just clocked into work. He starts each shift with a quick briefing between him and the previous shift. This catches him up on the tasks completed the day/night before and what he can expect for the day/night ahead.
Once they are caught up and have their marching orders, the team disperses and gets to work. Operators wear many hats, and day-to-day tasks vary. Here are some of the duties he might be assigned to cover:
- Clean, inspect and service equipment such as boilers, centrifuges, heat exchangers, reactors, tanks, and valves.
- Monitor and adjust machine parameters.
- Test batch quality and keep detailed records of results.
- Write permits that approve maintenance to work on equipment once it is deemed safe.
- Clean spills.
- Perform procedures to shut down a piece of equipment so that operators can perform maintenance safely.
- Operate the digital control boards. Here operators monitor the equipment performance and alert the outside team of any issues or concerns. There are many gauges, levels, and parameters to watch and analyze, which requires multitasking, making on-the-spot decisions, and acting quickly.
Each process operator is expected to take responsibility to manage themselves within their current assignment.
Hours as a Process Operator
Chemical plants never close. So process operators usually work twelve-hour shifts that cycle through a day and night combination. A quick example of that would be-
- Fr-Sat-Sun-Mon– Nightshift
- Tues-Wed-Thurs– OFF
- Fri-Sat-Sun– Day shift
- Mon– OFF
- Tues-Wed-Thurs– Nightshift
- Fri-Sat-Sun– OFF
Anthony works from 6am/pm- 6 pm/am.
His schedule includes one consecutive week off each month, which is a pretty cool bonus.
Most of the time, there is ample opportunity for overtime shifts. Anthony and his co-workers can volunteer for available shifts, but management forces them to cover any unclaimed days. As you can see, this job can be unpredictable, and he often misses out on events like birthdays, holidays, and other important dates.
BUT on the other hand, working longer days amounts to working fewer days. Without overtime, Anthony works only six months out of the year… fourteen days a month.
Shutdowns/Turnarounds
From time to time, shutting down an entire unit is necessary to do a deep clean or heavy maintenance. During a shutdown (also referred to as turnarounds), the operator’s schedule changes to “14-1,” which means you only get one day off every fourteen days.
Last year, Anthony worked a day shift turnaround from April- September. It was hard on us as a family but great for the bank account… Pros and cons.
Routines
For the most part, routines aren’t really a thing. The shift change and safety meetings are really the only constants for a chemical plant.
Sleep schedules can be challenging since you are cycling through the day and nighttime shifts. For Anthony, a dark room is essential to get a good day’s rest while working nights.
He packs a lunch, complete with snacks, drinks coffee before every shift, and eats many of the same foods, so I suppose that would be considered routine.
Work Environment
Refineries can be especially dangerous and volatile. Strictly enforced policies and procedures keep everyone safe from disasters, which could be severe or even fatal.
One wrong move and your skin is burning off. No, really… It’s pretty scary. Anthony has mentioned once or twice that if some of the chemicals touch your skin, “it doesn’t stop until it hits bone.”
So obviously, no slacking off.
Security is serious, and each employee must pass a government screening to qualify for a unique I.D. called a TWIC card, issued by the Transportation Worker Identification Credential.
Anthony enters and exit’s the plant through a guarded gate (using said I.D.) and is not permitted to leave during his shift, hence the packed lunch routine.
The plant is swarming with process operators and contractors, engineers, management, and utility teams. Keeping the plant running without error is a team effort, and all departments work together regularly.
Attire
The company typically provides work clothes. Anthony wears fire retardant long sleeve shirts and jeans or zip-up coveralls. This is a mandatory uniform.
Personal protection equipment (PPE) is required and supplied by the employer as well. For example, goggles protect your eyes from hazards such as airborne chemicals, should they be released. Earplugs protect your eardrums from damage as it is a loud work environment.
And sometimes, even head-to-toe acid suits, complete with footies, are required when in close proximity to dangerous chemicals.
Manual and Physical Labor
Being a process operator is hard work. Anthony is typically doing manual labor, such as turning huge valves, climbing ladders, repairing equipment, and standing for long hours. The plant requires constant maintenance and attention.
The field crew and operators use radios for easy and secure communication throughout the day. And workers often ride bikes to get around since it is such a massive complex.
Education
Anthony got a lucky break and was hired without finishing college (10 years ago); however, a degree is now required to be hired as a Process Technician/ Process Operator.
A two-year technical degree will do the trick but be careful; Anthony has heard that some teachers lead students to believe that being an operator is a cake job.
The general perception is that operators are sitting around in a control room while everything runs smoothly. That sentiment is far from the truth. It’s important to understand that there is much more to the job than sitting behind a control board.
As with most industries, the bulk of your training is on the job. In addition, each specific position requires new hires to be officially “qualified,” which means they cannot perform the task alone until a supervisor signs off on them.
Lifestyle
I did a quick Google search, and apparently, everything really is bigger in Texas. According to the internet, the average salary for a Process Operator in the U.S is approximately 42k-64k, which is a pretty good living. But in Texas, many operators are clearing six figures thanks to overtime hours.
(Overtime pays time-and-a-half, which is 1.5x hourly wage. So, for example, if you make $40/ hr, overtime pay would be $60/hr.)
As a beginner, it takes time to work your way up the salary board. Each year Anthony gets a “cost of living” raise, which is around 3%, in addition to a performance raise.
We are a two-income household (except for 2020), but Anthony has always made significantly more than me. Together we are in our second home, drive nice vehicles, buy whatever we want at the grocery store, and even go on awesome vacations. All this while building savings and being mostly debt-free.
That said, we are a very frugal couple. We keep ourselves on a budget and are careful with what we spend. But, as you know, lifestyle depends largely on your habits.
Certainly, some operators live paycheck-to-paycheck, paying for expensive toys like boats and sports cars, partying, and splurging. Not that there is anything wrong with that. You do you.
Can A.I. Take Your Job One Day?
Anthony says no. I don’t believe him. So much of the job requires critical thinking but will that be needed if artificial intelligence can keep the machines running without error? I guess we will settle the argument in a few decades.
Features and Benefits
The money is good, but it can be hard on your family, working long hours, missing birthday parties and holidays. On the flip side, you have days off in the middle of the week while everyone else is at work. The flexibility makes it easier to make appointments, avoid crowds and play a round of golf during the week.
In addition, your schedule includes a seven-day break every month, which allows for a long decompression or even a nice vacation without having to take time off.
Companies typically offer good health insurance and 401ks. You can also expect paid time off, including sick days and personal holidays. But, of course, many operators consider all that overtime a perk, too, since it allows them to beef up their paychecks.
Opportunity for Growth
Process operators have the opportunity to apply for other positions within the company as they come up. Team lead, supervisor, utilities manager, and training positions are a few that come to mind.
Each of them offers different hours and salaries. Some even provide a more traditional M-F schedule. As you can imagine, the competition can be tough, so it often takes time and experience before qualifying for advanced positions.
Anthony has applied for a couple, but he has lost out to coworkers with seniority so far.
Who are you serving?
Anthony’s plant, in particular, plays a significant role in creating the components needed to create plastics distributed around the world.
I consulted the company website and learned that their chemicals are components in products like automotive parts, antifreeze, lubricants and detergents, food and beverage containers, caps and closures, textiles and carpeting, and so much more.
Got Questions?
Everyone’s reality is unique, so please keep in mind that this is only one account, one perspective, and one life. But now you know the basics and possibilities! So tell me, do you think a career as a Process Operator is for you?
Let me know! Your feedback is welcomed, and I would love to know what else I could add to make this as thorough and interesting as possible.
We are happy to answer your questions and fill in any gaps, ask away
