Chemical processing plant controller

Chemical processing plant controllers control the chemical production process. They operate machines and systems, being responsible for monitoring and maintaining the equipment and the instruments in control.

The following job titles also refer to chemical processing plant controller:

chemical operator
chemical plant process operator
chemical plant and systems operator
chemical plant operator
chemical plant systems technician
chemical plant and systems monitor
chemical plant operations technician
chemical plant and systems monitoring technician
chemical plant and system operator
process plant operator

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Chemical processing plant controller is a Skill level 3 occupation.

These occupations, although different, require a lot of knowledge and skills similar to chemical processing plant controller.

gas station operator
air separation plant operator
chemical plant control room operator
chemical processing supervisor
chemical manufacturing quality technician

These occupations require some skills and knowledge of chemical processing plant controller. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of chemical processing plant controller with a significant experience and/or extensive training.

chemical production manager
analytical chemist
gambling, betting, and lottery quality assurance engineer
assayer
pharmaceutical quality specialist

This knowledge should be acquired through learning to fulfill the role of chemical processing plant controller.

• Good manufacturing practices: Regulatory requirements and Good Manufacturing Practices (GMP) applied in the relevant manufacturing sector.
• Chemical processes: The relevant chemical processes used in manufacture, such as purification, seperation, emulgation and dispergation processing.
• Manufacturing plant equipment: The characteristics and functioning conditions of manufacturing plant equipments such as chemical reactors, addition tanks, pumps, filters, mixers.
• Basic chemicals: The production and characteristisc of organic basic chemicals such as ethanol, methanol, benzene and inorganic basic chemicals such as oxygen, nitrogen, hydrogen.

These skills are necessary for the role of chemical processing plant controller.

• Optimise production processes parameters: Optimise and maintain the parameters of the production process, such as flow, temperature or pressure.
• Cope with manufacturing deadlines pressure: Cope with a tight schedule on the manufacturing processes level and take the necessary actions when deadlines approach or when some processes fail.
• Use ICT systems: Select and use ICT systems for a variety of complex tasks in order to meet a variety of needs.
• Monitor manufacturing quality standards: Monitor quality standards in manufacturing and finishing process.
• Adhere to standard procedures: Adhere to and follow the Standard Operating Procedures (SOP).
• Test chemical samples: Perform the testing procedures on the already prepared chemical samples, by using the necessary equipment and materials. Chemical sample testing involves operations such as pipetting or diluting schemes.
• Manage chemical testing procedures: Manage the procedures to be used in chemical testing by designing them and conducting tests accordingly.
• Use chemical analysis equipment: Use the laboratory equipment such as Atomic Absorption equimpent, PH and conductivity meters or salt spray chambre.
• Prepare chemical samples: Prepare the specific samples such as gas, liquid or solid samples in order for them to be ready for analysis, labeling and storing samples according to specifications.
• Test production input materials: Test the supplied materials prior to their release into processing, ensuring the results are complying with GMP (Good Manufacturing Practices) and to the suppliers` COA (Certificate of Analysis).
• Monitor chemical process condition: Monitor the conformity of the chemical process, checking all indicators or warning signals provided by the instruments such as recording instruments, flowmeters and panel lights.

This knowledge is sometimes, but not always, required for the role of chemical processing plant controller. However, mastering this knowledge allows you to have more opportunities for career development.

• Mathematics: Mathematics is the study of topics such as quantity, structure, space, and change. It involves the identification of patterns and formulating new conjectures based on them. Mathematicians strive to prove the truth or falsity of these conjectures. There are many fields of mathematics, some of which are widely used for practical applications.
• Energy efficiency: Field of information concerning the reduction of the use of energy. It encompasses calculating the consumption of energy, providing certificates and support measures, saving energy by reducing the demand, encouraging efficient use of fossil fuels, and promoting the use of renewable energy.
• ICT software specifications: The characteristics, use and operations of various software products such as computer programmes and application software.
• Multimedia systems: The methods, procedures and techniques pertaining to the operation of multimedia systems, usually a combination of software and hardware, presenting various types of media such as video and audio.
• Hazardous waste storage: The regulations and procedures surrounding the safekeeping of materials and substances which pose health and safety risks.
• Mechanics: Theoretical and practical applications of the science studying the action of displacements and forces on physical bodies to the development of machinery and mechanical devices.

These skills and competences are sometimes, but not always, required for the role of chemical processing plant controller. However, mastering these skills and competences allows you to have more opportunities for career development.

• Develop energy saving concepts: Use current research results and collaborate with experts to optimise or develop concepts, equipment, and production processes which require a lesser amount of energy such as new insulation practices and materials.
• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Perform risk analysis: Identify and assess factors that may jeopardise the success of a project or threaten the organisation’s functioning. Implement procedures to avoid or minimise their impact.
• Oversee production requirements: Oversee production processes and prepare all the resources needed to maintain an efficient and continuous flow of production.
• Operate forklift: Operate a forklift, a vehicle with a pronged device in front for lifting and carrying heavy loads.
• Control minor maintenance: Follow up on the maintenance and repairs to be carried out. Solve minor problems and pass harder problems on to the person responsible for maintenance.
• Manage chemical processes inspection: Manage the chemical in-process inspection, making sure the inspection results are documented, the inspection procedures are well written and the checklists are updated.
• Write batch record documentation: Write reports on the manufactured batches history taking into account the raw data, tests performed and compliance to GMP of each batch of product.
• Clean mixer: Perform the cleaning of mixers in order to prepare them for mixing different types of compounds.

3133 – Chemical processing plant controllers

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References

1. Chemical processing plant controller – ESCO