Chemical plant process workers operate machinery and monitor equipment which process and mix chemicals. Some companies create sophisticated chemicals which help to make pharmaceuticals, soaps, toiletries and cleaning products. Others mix chemicals together to make finished products such as paints, plastics and fertilisers.
A process worker’s job may involve:

Process workers work a basic 38-hour week, and shift work is common. Chemical plants are often modern and clean, although there are some older, dirtier plants. The work may involve climbing stairs and standing for long periods.
Salaries range from around £18,000 to £28,000 a year.

Chemical plant process workers need to be: able to cope with regular routines patient, careful and methodical good at using computers interested in science and technology.

The chemical industry is one of Britain’s largest manufacturing industries, and around 130,000 people are employed as process plant operators. Chemical companies can be found almost everywhere in the UK, with the heaviest concentrations of industry in the north west and north east of England, and in Scotland. Employers range from big multinational chemical and oil companies, to specialist small businesses.
Applicants aged 16 or over can join the chemical industry directly, often as a trainee or apprentice. There are no formal educational requirements, but some companies ask for GCSEs/S grades (A-D/1-4) in maths and science subjects. Good eyesight and colour vision is needed to read meters, dials and instrument charts. There is no upper age limit.
There is a variety of training schemes in the chemical industry such as National Traineeships, which lead towards NVQ/SVQ Level 2, and full-time college courses sponsored by an employer. All training covers health and safety and basic chemical processes. Trainees may shadow an experienced worker.
Promotion may be possible from plant operator to plant controller, senior controller and shift supervisor. Graduate chemists or chemical engineers normally hold plant manager positions.

What is the work like?
Chemical plant process workers operate machinery and monitor equipment which process and mix chemicals.
The chemical industry refines substances, such as oil and natural gas, to make base chemicals. Some companies use these base chemicals to create more sophisticated chemicals which help to make pharmaceuticals, soaps, toiletries and cleaning products.
Others mix chemicals together to make finished products such as paints, plastics, fertilisers, dyes, polishes, cosmetics and even man-made fibres for the clothing and fashion industry.
The work varies depending on the type of equipment that is being used, and a process worker’s job may involve:

Many of these tasks will be done from a computer control room.
Other jobs may include:

Some of the work can be repetitive, using written procedures and formulas which must be followed closely.
Workers may also have to carry out minor maintenance work or report more serious faults to an engineering maintenance fitter. At night, although the plant may be floodlit, parts may remain dark, so a torch will be needed to examine pipework and equipment.
Salaries for chemical plant process operators start at around £18,000 a year.

Hours and environment

Process workers work a basic 38-hour week. Plants normally operate 24 hours a day, seven days a week, so shift work is common. This may involve night and weekend work and there may be opportunities for overtime. Shifts may be as long as 12 hours, but shift allowances are usually paid.
They work inside and outside, as plants may be partly covered or totally enclosed. The indoor control room is dry, clean and usually air-conditioned because of electronic equipment.
Chemical plants are often modern and clean, although there are some older, dirtier plants, which may be affected by dust, fumes, noise or heat.
The work may involve climbing stairs and walking long distances along catwalks high above the ground. Lifting, and sitting or standing for long periods, may also be involved.
Process workers usually wear protective overalls, such as helmets and boots, as some chemicals are hazardous.

Salary and other benefits

These figures are only a guide, as actual rates of pay may vary, depending on the employer and where people live.

Overtime and productivity payments are often available.

Skills and personal qualities

Chemical plant process workers need:

Interests

It helps to have an interest in:

Getting in

The chemical industry is one of Britain’s largest manufacturing industries. Around 130,000 people are employed as process plant operators, although numbers have been declining.
Chemical companies can be found operating almost everywhere in the UK. The heaviest concentrations of industry are in the north west and north east of England, and in Scotland. It tends to cluster in favoured locations. This may be because raw materials are readily available, there are good transport systems nearby, or there is a concentration of customers in the locality.
Employers range from big multinational chemical and oil companies to specialist small and medium-sized businesses. Applications for employment should be made directly to their head offices or local operations. With the multinationals, there may be opportunities to work abroad.

Entry for young people
Applicants aged 16 or over can join the chemical industry directly, usually starting as a trainee or apprentice.
There are no formal educational requirements, although basic numeracy and literacy skills are an advantage. Some companies ask for GCSEs/S grades (A-D/1-4) in maths and science subjects, and competition for jobs means that applicants with qualifications have an advantage.
Applicants may be asked to take numeracy and general intelligence tests and undergo a medical to make sure they are fit enough to perform the job. Regular medical examinations may be carried out throughout employment.
Good eyesight and colour vision is needed to read meters, dials and instrument charts.
Apprenticeships which may be available in England are Young Apprenticeships, Pre-Apprenticeships, Apprenticeships and Advanced Apprenticeships. To find out which one is most appropriate log onto www.apprenticeships.org.uk or contact your local Connexions Partnership.
There are different arrangements for Apprenticeships in Scotland, Wales and Northern Ireland. For further information contact Careers Scotland www.careers-scotland.org.uk, Careers Wales www.careerswales.com; and for Northern Ireland contact COIU www.delni.gov.uk.

Entry for adults
There is no upper age limit for entry into the profession. Many employers recruit people over 18 (and, in some cases, over 23) who have had at least one other job since leaving school. Many firms welcome mature applicants.

Training

There is a variety of training schemes in the chemical industry:

All training covers health and safety and basic chemical processes. Trainees may shadow an experienced worker, watching what they do and learning from them, before carrying out set tasks under supervision.
Training also covers personal safety, such as how to use breathing apparatus, general first aid, and how to work effectively and safely in confined spaces.
In some plants, there may be day release to study for a City & Guilds qualification in, for example, Instrumentation and Control, Materials Processing, Industrial Studies or Scientific Calculation.
NVQs/SVQs in Process Operations at Levels 1, 2 and 3 may also be available through assessment on the job.
It is sometimes possible for process operators with NVQs/SVQs at Level 3 to study for higher national certificates or degree qualifications. BTEC/SQA Higher National Certificate courses in Chemical Process operations are available at some colleges.

Getting on

Promotion may be possible from plant operator to plant controller, senior controller and shift supervisor. Graduate chemists or chemical engineers normally hold plant manager positions.

Further information

The Association of the British Pharmaceutical Industry (ABPI), 12 Whitehall, London SW1A 2DY. 020 7930 3477. Website: www.abpi.org.uk
Chemical Industries Association ( CIA), Kings Buildings, Smith Square, London SW1P 3JJ. 020 7834 3399. Websites: www.cia.org.uk
Cogent SSC Ltd, Minerva House, Bruntland Road, Portlethen, Aberdeen AB12 4QL. 01224 787800. Website: www.cogent-ssc.com
Royal Society of Chemistry, Burlington House, Piccadilly, London W1J 0BA. 020 7437 8656. Website: www.rsc.org

Further reading

Working in manufacturing - Connexions
Working in science – Connexions

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http://www.connexions-direct.com/

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