Separating, Filtering, Clarifying, Precipitating, and Still Machine Setters, Operators, and Tenders Salary

Q: Which state pays separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss the most?

The highest paying state for separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss is Wyoming at $108,900 median salary.

Q: What interview questions are asked for separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders roles?

Common separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders interview questions include: "Walk me through a start-up or shut-down you've participated in.", "Describe an alarm-response event you handled.", "Describe a safety incident or near-miss you observed and how it was handled.". Interview format at top employers ranges from behavioral panels (STAR method) to technical case rounds — for example Petroleum Refining Majors (ExxonMobil, Chevron, Marathon Petroleum, Valero, Phillips 66, HF Sinclair, PBF Energy, Delek US) typically uses 3-5 rounds over 4-8 weeks.

Q: What is the career ladder for separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss?

The typical separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders career ladder: Outside Operator / Field Operator / Tender (0-5 yrs, $22-28/hr ($46-58k) + shift differential + full benefits + pension or 401(k) match at USW / ICWUC / Teamsters employers) → Assistant Console Operator / Board-Trainee (3-6 yrs, $28-34/hr ($58-71k) + shift differential + full benefits + LTIP eligibility at Fortune-500 employers) → Console Operator / Board Operator (5-11 yrs, $34-42/hr ($71-87k) + shift differential + full benefits + LTIP + $12-30k annual OT typical) → Sr Operator / Lead Operator / Console Supervisor (8-16 yrs, $42-52/hr ($87-108k) + shift differential + full benefits + LTIP + $15-40k annual OT typical).

Q: What certifications should separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss get?

Top-ROI certifications for separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss: AAS Process Technology (NAPTA-aligned curriculum) ($4-14k total tuition (Pell Grant eligible at accredited schools); often subsidized to $0-5k through Section-127 tuition support at Fortune-500 employers; 18-24 months); HAZWOPER 40-hr initial training + 8-hr annual refresher (29 CFR 1910.120) ($600-1,400 initial + $200-450 annual refresher; typically employer-paid; 40 clock-hours initial + 8 clock-hours refresher); OSHA 30 Petrochemical (or OSHA 30 General Industry with Petrochemical emphasis) ($150-350; online through OSHA-authorized outreach trainers; 30 clock-hours).

The median separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders salary in the United States is $51,610 per year ($24.81/hour). Salaries range from $36,200 at the entry level to $79,750+ for the top 10% of earners. There are 60,100 separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders jobs nationwide. Employment is projected to decline 4.3% through 2034.

Last updated: June 2026 · Source: U.S. Bureau of Labor Statistics

Median Salary

$51,610

per year

Hourly Rate

$24.81

per hour

Employment

60,100

jobs in the U.S.

Salary Distribution

10th percentile

$36,200

25th percentile

$44,410

Median

$51,610

75th percentile

$63,930

90th percentile

$79,750

Job Growth (2024-2034)

-4.3%

Decline

Annual Openings

5,400

jobs/year (growth + replacements)

Education Required

High school diploma or equivalent

Training Needed

Moderate-term on-the-job training

Separating, Filtering, Clarifying, Precipitating, and Still Machine Setters, Operators, and Tenders Career Guide

Interview questions, resume templates, and a career ladder written specifically for separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenderss.

Separating, filtering, clarifying, precipitating, and still machine operators (BLS SOC 51-9012) run the unit-operations equipment that separates process streams — centrifuges (Alfa Laval, GEA Westfalia, Andritz), filter presses (Andritz, JWI, Micronics), belt presses, disc-stack separators, decanters, crystallizers, distillation columns, evaporators, dryers, and cyclones — at petroleum refineries (ExxonMobil, Chevron, Valero, Marathon Petroleum, Phillips 66, HF Sinclair), chemical processors (Dow, LyondellBasell, INEOS, BASF, Eastman, Celanese, Olin), pharmaceutical manufacturers (Merck, Pfizer, Johnson & Johnson, Eli Lilly, AbbVie, Bristol-Myers Squibb, Amgen), and food / beverage / dairy processors (Cargill, ADM, Land O'Lakes, Kraft-Heinz, Constellation Brands, Anheuser-Busch InBev). BLS reports 60,100 employed with a median of $51,610, p10 $37,090, p90 $77,540+. Entry Outside Operator / Tender $22-28/hr ($46-58k); established Board / Console Operator $28-38/hr ($58-79k); Sr Operator / Lead $38-48/hr ($79-99k); Shift Supervisor / Console Supervisor $48-62/hr salaried ($99-129k+). Petroleum-refinery and chemical-processing seats at OSHA PSM 29 CFR 1910.119-covered facilities pay 30-60% above general-industry separating / filtering seats — the same operator seat at a refinery clears $95-145k with overtime and shift premium vs $58-78k at a general food-processing plant. Union representation at USW (which absorbed PACE — Paper, Allied-Industrial, Chemical, and Energy Workers), ICWUC (International Chemical Workers Union Council), Teamsters, and UFCW at many refineries and chemical plants pushes base 15-30% higher with pension and healthcare. The biggest earnings lever is stacking a HAZWOPER 40-hr + OSHA PSM familiarization + moving from a general food-processing plant into a USW / ICWUC refinery or chemical-processing seat.

Core Skills Hiring Managers Screen For

OSHA Process Safety Management (PSM) 29 CFR 1910.119 discipline

OSHA PSM applies to any facility with a threshold quantity of a highly hazardous chemical listed in Appendix A (e.g., 1,500 lb ammonia, 10,000 lb chlorine, 15,000 lb hydrogen fluoride, 10,000 lb pentane) and to processes involving flammable liquids or gases in quantities of 10,000 lb or more — covers essentially every petroleum refinery and most chemical / pharmaceutical processing facilities. The 14 PSM elements: (1) Employee Participation; (2) Process Safety Information (PSI — P&IDs, MOCs, chemical hazard data, equipment design basis); (3) Process Hazard Analysis (PHA — HAZOP, What-If, LOPA, revalidated every 5 years); (4) Operating Procedures; (5) Training; (6) Contractors; (7) Pre-Startup Safety Review (PSSR); (8) Mechanical Integrity (MI — inspection, testing, preventive maintenance on critical equipment); (9) Hot Work Permit; (10) Management of Change (MOC — engineering / procedural / organizational changes require formal PSM review); (11) Incident Investigation; (12) Emergency Planning and Response; (13) Compliance Audits (every 3 years); (14) Trade Secrets. EPA Risk Management Program (RMP) 40 CFR Part 68 parallels PSM at threshold quantities under CAA §112(r); RMP submission every 5 years.

HAZWOPER 40-hr initial + 8-hr annual refresher (29 CFR 1910.120)

OSHA Hazardous Waste Operations and Emergency Response standard 29 CFR 1910.120 governs work at hazardous-waste sites and emergency response at any facility with a chemical release. HAZWOPER 40-hr initial training (typical $600-1,400 through OSHA-authorized outreach trainers — International Chemical Workers Union Council, University of Cincinnati Environmental Health, RedVector, HSI Vivid) required for site workers; HAZWOPER 8-hr annual refresher required to maintain the certification. HAZWOPER-Supervisor 8-hr additional training required for supervisors and shift leads. Skills covered: hazard recognition, PPE selection (Level A / B / C / D per EPA / OSHA nomenclature), decontamination procedures, air-monitoring instrumentation (4-gas monitor — O2 / LEL / CO / H2S, PID for VOC, colorimetric detector tubes for specific compounds), site-control zones (Exclusion / Contamination-Reduction / Support), emergency-response levels (Awareness, Operations, Technician, Specialist, Incident Commander), spill / release response, medical-surveillance requirements.

Centrifuge, filter press, and separation-equipment operation

Disc-stack centrifuges (Alfa Laval, GEA Westfalia, Tomoe, Pieralisi) for continuous liquid-liquid or liquid-solid separation in dairy, edible-oil, biodiesel, pharmaceutical, and petroleum applications — bowl speed 4,000-10,000 RPM; automatic solids discharge (nozzle / self-cleaning) intervals; back-pressure control on the light and heavy phase discharge; bowl-balance and vibration monitoring per API 617 / API 620. Decanter centrifuges (Alfa Laval, Andritz, GEA, Flottweg) for continuous solids-dewatering in wastewater, pharmaceutical, food-processing, and mining — bowl 3,000-5,000 RPM; differential speed on scroll conveyor; pond depth adjustment. Filter presses (Andritz, JWI, Micronics, Metso, Larox) for batch solids-recovery in pharmaceutical, chemical, mineral-processing, and wastewater — plate-and-frame or membrane press design; automatic plate-shifter; cake wash and blow-dry cycles; cloth change-out every 200-800 cycles. Belt presses (Ashbrook Simon-Hartley, Andritz, BDP) for continuous wastewater biosolids dewatering. Cyclones and hydrocyclones (Krebs / FLSmidth, Weir Minerals, Salter Cyclones) for gas-solid or liquid-solid separation. Screens and vibratory separators (Sweco, Rotex, Kason) for particle-size classification.

Distillation column operation and reflux-ratio control

Distillation columns (crude atmospheric distillation at petroleum refineries, vacuum-distillation, fractionators, rectifiers, strippers) — 20-80 trays typical for petroleum applications; packed columns for chemical / pharmaceutical / edible-oil applications; feed-tray location; reflux ratio (L/D typically 1-15 depending on separation difficulty); reboiler duty (typically steam-heated at refinery scale, some electric-heated at pharmaceutical scale); condenser duty; top and bottom temperature and pressure profile monitoring; flooding and weeping detection through differential pressure across the column; column-turnaround inspection every 3-6 years. Vacuum-distillation (VDU) at refinery for gas-oil separation from atmospheric-tower bottoms; typical operating pressure 25-40 mmHg absolute; steam-ejector or liquid-ring-vacuum-pump vacuum systems. Reactive-distillation at pharmaceutical / chemical for combined-reaction-and-separation.

Crystallization and evaporation equipment

Crystallizers — forced-circulation (FC), draft-tube-baffled (DTB), Oslo, and pilot-plant designs — for continuous or batch crystallization of pharmaceutical APIs, agricultural chemicals, salts, and sugars. Control parameters: supersaturation profile (temperature, evaporation, or antisolvent addition), seed-crystal introduction, residence-time-distribution, crystal-size-distribution (CSD) via laser particle-size analyzer or Malvern Mastersizer. Evaporators — falling-film, rising-film, forced-circulation, mechanical-vapor-recompression (MVR) — for concentration of dairy, chemical, and pharmaceutical process streams. Multiple-effect evaporators (typical 3-6 effects) for steam economy at food / dairy scale (Land O'Lakes, Dairy Farmers of America, Cargill dairy).

Distributed Control System (DCS) and console operation

DCS platforms in the petroleum-refinery and chemical-processing space: Honeywell Experion PKS + TDC 3000 legacy; Emerson DeltaV + Ovation; Yokogawa CENTUM VP; ABB 800xA; Siemens PCS 7. Console-operator responsibilities: monitor 60-300 control loops per unit; alarm-response discipline (alarm rationalization per ISA 18.2 / IEC 62682 — typical target <150 alarms per operator per hour, actionable-alarm design); trend-analysis on critical process variables (feed rate, pressure, temperature, level, composition); coordinate outside operators on field actions (valve manipulation, sampling, minor local intervention); execute unit start-up, shut-down, and emergency-response procedures. Console-Operator seats are typically bid-based within a unit's operator ladder — 3-5 years as Outside Operator, then 2-4 years as Assistant Console, then Console Operator.

Sampling and quality-control lab interface

Process-sampling for lab QC — hourly, per-shift, per-batch, or event-driven sampling per the unit's QC plan; specific-gravity, viscosity, pH, conductivity, water-content (Karl Fischer titration), and composition (GC, GC-MS, HPLC, ICP-MS) sampling with proper container, preservation, and chain-of-custody. Refinery-specific: octane / cetane / RVP (Reid vapor pressure), flash point (Pensky-Martens, Tag), pour point, sulfur (ASTM D5453 UV fluorescence), water content (ASTM D6304 Karl Fischer). Pharmaceutical-specific: ICH Q7 GMP sampling for API intermediates; USP monograph testing for pharmacopeial compliance; QP release testing per EU / FDA regulations. Food / dairy-specific: microbial testing (aerobic plate count, coliforms, Salmonella, Listeria), somatic-cell count (dairy), moisture (Karl Fischer or oven), fat (Mojonnier or Babcock), protein (Kjeldahl or combustion).

Mechanical Integrity (MI) program participation and PM discipline

PSM Element 8 Mechanical Integrity — inspection, testing, and preventive maintenance on critical equipment (pressure vessels, storage tanks, piping, relief devices, emergency shutdown systems, DCS, rotating equipment). Operator role: report-and-tag any deviation from design condition, complete daily / weekly equipment checks per the MI plan, participate in inspection walk-downs with the mechanical-integrity engineer, execute lockout / tagout (29 CFR 1910.147) for turnaround maintenance. API-related inspection standards: API 510 pressure-vessel inspection; API 570 piping inspection; API 653 storage-tank inspection; API 579 fitness-for-service evaluation; API 580/581 risk-based inspection (RBI). Turnaround discipline — planned unit shutdowns every 3-6 years for major inspection, catalyst replacement, and repair; the unit operator is a critical stakeholder in turnaround planning, execution, and startup.

How to Become a Separating, Filtering, Clarifying, Precipitating, and Still Machine Setters, Operators, and Tenders

1
Complete a high-school diploma or GED with strong math, chemistry, and reading-comprehension foundations
Employers screen on shop-math ability (fractions, decimals, unit conversion, basic algebra), chemistry-101 fluency (moles, molarity, gas laws, unit-operations basics), and reading-comprehension (procedures, P&IDs, MSDS / SDS). A high-school co-op or vocational-track program in process technology, industrial technology, or chemical technology is a meaningful head start. Some employers accept a WorkKeys National Career Readiness Certificate at Silver or Gold as an alternate signal.
2
Complete a technical certificate or Associate's in Process Technology, Chemical Technology, or Industrial Operations (strongly preferred)
Process Technology AAS programs at Lee College (Baytown, TX — the flagship refinery / chemical-plant training program in the Houston Ship Channel), Alvin Community College, San Jacinto College, Lamar Institute of Technology (Beaumont, TX — Golden Triangle refining corridor), Baton Rouge Community College (LA — chemical alley), West Virginia University at Parkersburg, Delta College (MI — chemical / pharmaceutical), Del Mar College (Corpus Christi, TX), Bismarck State College (ND — Bakken refining) — 18-24 months, $4-14k tuition + textbooks (Pell Grant eligible). NAPTA (North American Process Technology Alliance) curriculum standard aligns most Process Technology AAS programs across the country. Some employers (ExxonMobil, Chevron, Marathon Petroleum, Dow, LyondellBasell) run their own in-house Process Technology apprenticeships at 24-36 months paid $22-32/hr during apprenticeship.
3
Start as Outside Operator / Field Operator / Tender at $22-28/hr ($46-58k) + shift differential + benefits
First seat — typical at a Houston / Gulf Coast / Golden Triangle / Chemical Alley refinery (ExxonMobil Baytown, Chevron Pascagoula, Marathon Petroleum Galveston Bay / Garyville, Phillips 66 Bayway / Sweeny, Valero St. Charles / Port Arthur, HF Sinclair Tulsa / El Dorado), a chemical plant (Dow Freeport / Plaquemine, LyondellBasell La Porte / Channelview, INEOS Chocolate Bayou, BASF Freeport / Geismar, Eastman Kingsport, Celanese Bay City, Olin Freeport), a pharmaceutical manufacturer (Merck Elkton / West Point / Rahway, Pfizer Kalamazoo / Groton, J&J New Brunswick, Lilly Indianapolis / Branchburg, AbbVie North Chicago, BMS Syracuse / New Brunswick, Amgen Thousand Oaks / Juncos), or a food / dairy / beverage processor (Cargill / ADM oilseed and grain, Land O'Lakes / Dairy Farmers of America dairy, Kraft-Heinz processing, AB InBev / Constellation Brands beverage). Duties: field rounds, valve manipulation on operator-authorized valves, sampling, local instrument reading, tank-farm gauging, unit start-up and shut-down support. Shift differential $1-3/hr for 2nd and 3rd shift; overtime at 1.5x after 40 hrs (many USW / ICWUC CBAs have 1.5x after 8/day and 2x on Sundays).
4
Layer on HAZWOPER 40-hr + OSHA PSM familiarization + specific unit training
HAZWOPER 40-hr initial training (typical $600-1,400 through ICWUC, University of Cincinnati EHS, RedVector, HSI Vivid) at year 1; 8-hr annual refresher to maintain. OSHA PSM familiarization curriculum (typical 16-40 hr through the site EHS department or ICWUC PSM training track) at year 1. Unit-specific training: crude atmospheric distillation, fluid catalytic cracker (FCC), hydrocracker, reformer, alkylation, coker, hydrotreater, sulfur recovery unit (SRU), gas-plant, isomerization, hydrogen-plant, wastewater treatment — each with its own written unit procedures, DCS graphics, and start-up / shut-down sequence. Pharmaceutical-specific: GMP training per 21 CFR Part 210/211; ICH Q7 API guidance. Food / dairy-specific: HACCP (Hazard Analysis Critical Control Points) 21 CFR Part 117; FSMA (Food Safety Modernization Act) preventive-controls curriculum.
5
Promote to Assistant Console Operator / Board-Trainee at $28-34/hr ($58-71k) + shift differential
3-5 years after entry. Cross-train on the DCS graphics, alarm-response procedures, and console-operator responsibilities on the assigned unit. Support the Console Operator on unit start-up, shut-down, and emergency-response drills. Complete unit-specific procedure-book review and demonstrated console-operation competency signed off by the unit Sr Operator and Shift Supervisor.
6
Promote to Console Operator / Board Operator at $34-42/hr ($71-87k) + shift differential + LTIP
5-9 years in seat. Own the DCS console on the assigned unit during the shift. Direct the Outside Operators on field actions. Execute unit start-up, shut-down, and emergency-response procedures. Interface with the Shift Supervisor, Unit Engineer, and Lab on process-quality issues. This is the seat where refinery / chemical-plant Operators cross the $85-105k annual earnings threshold with overtime and shift differential.
7
Advance to Sr Operator / Lead Operator / Console Supervisor at $42-52/hr ($87-108k) + shift differential + LTIP
8-15 years in seat. Second-chair the Shift Supervisor on operational decisions; train new Console Operators; own the unit's operating-procedure book updates; act as Shift Supervisor coverage on days off. Some employers layer this as a bargaining-unit Lead Operator classification; others move this seat into salaried Assistant Shift Supervisor. Union CBAs typically define this promotion through a written bid-and-qualification process.
8
Advance to Shift Supervisor / Console Supervisor / Unit Supervisor at $99-135k salaried + bonus + LTIP + equity
12-20 years in seat, typically with an AAS Process Technology + PSM Auditor certification (or equivalent) + demonstrated Console-Operator excellence. Own a shift's operation across the assigned unit or set of units; direct-manage 6-20 Outside and Console Operators. Some employers require an AAS or a 2-year certificate for the Supervisor promotion at OSHA PSM facilities. Bonus 10-18% on unit-level safety, environmental, throughput, and reliability metrics is typical.
9
Advance to Operations Superintendent / Unit Manager / Process Engineer at $135-215k+ + bonus + LTIP + equity
15-25 years in seat, typically with an AAS Process Technology + BS Chemical Engineering Technology (via employer tuition support) or an AAS + demonstrated leadership. Operations Superintendent owns a set of units and the shift-supervisor bench. Process Engineer owns the unit's process-parameter book, MOCs, and PHA participation. Corporate Operations Manager at ExxonMobil, Chevron, Marathon Petroleum, Dow, LyondellBasell, or Merck supports 3-10 sites on operational excellence, PSM, and reliability programs.

Career Progression

Outside Operator / Field Operator / Tender

0-5 yrs$22-28/hr ($46-58k) + shift differential + full benefits + pension or 401(k) match at USW / ICWUC / Teamsters employers

•Complete daily field rounds per the unit's rounds book; report deviations to the Console Operator
•Sample process streams for lab QC per the unit's sampling schedule
•Manipulate operator-authorized valves under Console Operator direction
•Support unit start-up, shut-down, and turnaround activities

Next: Assistant Console Operator / Board-Trainee at 3-5 years with HAZWOPER 40-hr + PSM familiarization.

Assistant Console Operator / Board-Trainee

3-6 yrs$28-34/hr ($58-71k) + shift differential + full benefits + LTIP eligibility at Fortune-500 employers

•Cross-train on the DCS graphics, alarm-response procedures, and console-operator responsibilities
•Support the Console Operator on start-up, shut-down, and emergency-response drills
•Complete unit-specific procedure-book review and demonstrated console-operation competency
•Continue field-operator rotation to maintain outside-operator competency

Next: Console Operator / Board Operator at 5-9 years with signed-off unit competency.

Console Operator / Board Operator

5-11 yrs$34-42/hr ($71-87k) + shift differential + full benefits + LTIP + $12-30k annual OT typical

•Own the DCS console on the assigned unit during the shift
•Direct the Outside Operators on field actions and coordinate with the Shift Supervisor
•Execute unit start-up, shut-down, and emergency-response procedures
•Interface with Unit Engineer, Lab, and Shift Supervisor on process-quality issues

Next: Sr Operator / Lead Operator at 8-15 years.

Sr Operator / Lead Operator / Console Supervisor

8-16 yrs$42-52/hr ($87-108k) + shift differential + full benefits + LTIP + $15-40k annual OT typical

•Second-chair the Shift Supervisor on operational decisions; train new Console Operators
•Own the unit's operating-procedure book updates and MOC participation
•Act as Shift Supervisor coverage on days off
•Own the unit's PSM Element 4 (operating procedures) and Element 5 (training) documentation

Next: Shift Supervisor / Unit Supervisor at 12-20 years.

Shift Supervisor / Unit Supervisor / Operations Superintendent

12+ yrs$99-165k salaried + 10-18% bonus + LTIP + full executive benefits at Fortune-500 OSHA-PSM employers

•Own a shift's operation across the assigned unit or set of units; direct-manage 6-20 operators
•Own shift-level safety, environmental, throughput, and reliability metrics
•Handle Step 1 union grievances, disciplinary write-ups, and attendance-policy administration under USW / ICWUC CBA
•Report to Operations Manager on daily operations, safety incidents, and reliability KPIs

Interview Questions & Answers

5 free questions below. Career Kit unlocks 13 total plus resume bullets for every level.

Q1. Walk me through a start-up or shut-down you've participated in.technical

Structured. Example: 'Marathon Petroleum Galveston Bay Refinery — Catalytic Reformer Unit start-up after a 42-day turnaround. My role: Outside Operator on the reactor section, year 4 in the operator ladder. Pre-startup safety review (PSSR) per PSM Element 7 with the Shift Supervisor, Unit Engineer, and Turnaround Coordinator; sign-off on completion of MOC action items and mechanical-integrity punch-list. Nitrogen-purge and leak-test on the reactor circuit at 250 psig; pull nitrogen certification samples for O2 < 0.5% at each reactor. Introduction of naphtha feed via feed pumps in slow-ramp per the unit's written start-up procedure — feed rate 15,000 BPD start, ramp to 45,000 BPD over 12 hr. Coordinate with Console Operator on reactor bed temperatures (typical 950-975°F) and hydrogen recycle rate (H2/HC ratio 4-6). Introduce chloriding agent (typically perchloroethylene) at spec-rate to reactivate the platinum catalyst. Watch for hot-spot development on reactor bed temperatures; call the Sr Operator if any bed shows >20°F deviation from the temperature profile. Shift-supervisor walk-through the unit at 4-hr intervals during the 24-hr start-up window. Result: unit online at 45,000 BPD within 24 hr of feed-in; no environmental exceedances; no unit trips. Interviewers screen for candidates who cite specific unit sequence, specific temperature and pressure targets, specific PSM element numbers, and specific coordination with the Console Operator.

Q2. Describe an alarm-response event you handled.situational

Structured. Example: 'Distillation column bottom-level high-high alarm at a Dow chemical plant Freeport site — the debutanizer bottom-level rose from 65% to 92% in 8 minutes, tripping the high-high alarm. Response sequence: (1) Immediate acknowledge on the DCS; do not silence-and-forget. (2) Cross-check the level with the redundant transmitter (Rosemount 3051 vs Rosemount 3095 differential-pressure vs radar) — level was real, not instrument fault. (3) Verify feed rate has not spiked — feed was steady at 12,500 lb/hr. (4) Check the bottoms-pump discharge flow — the flow-controller output was at 100% but the flow was 40% below setpoint; the pump was cavitating on suction. (5) Check pump suction pressure — pressure was 4 psig, well below the pump's NPSH-required of 12 psig. (6) Direct the Outside Operator to check the pump suction strainer — strainer was 80% blocked with polymer solids. (7) Initiate the pump-switchover sequence to the spare pump per the unit's written procedure; open pump-suction-strainer cleaning ticket for maintenance next shift. (8) Level normalized to 68% within 25 minutes of alarm. (9) Document the event in the shift log and the alarm-response log per PSM Element 11 (Incident Investigation) if the level had exceeded 95% (would have tripped column feed via the ESD system). Interviewers screen for candidates who describe the specific alarm-management discipline per ISA 18.2, the redundant-transmitter cross-check, and the escalation to the ESD trip logic — not who wave through 'I noticed the level was high and switched to the spare pump.'

Q3. Describe a safety incident or near-miss you observed and how it was handled.behavioral

STAR. Situation: Console Operator at an ExxonMobil Baytown Refinery Fluid Catalytic Cracker (FCC) unit. Task: identify and report a near-miss involving a maintenance-worker's LOTO isolation on the wet-gas compressor. Action: (1) noticed on the DCS that the wet-gas-compressor lube-oil-pressure permissive had gone to 'bypass' at 03:15 shift; investigated because no MOC or Work Order had been logged for the shift. (2) Radioed the Outside Operator to walk the compressor deck and verify the LOTO isolation. (3) Outside Operator reported that a maintenance-worker had applied a personal lock to the compressor MCC disconnect but had left the DCS-level permissive in bypass without an operations sign-off. (4) I escalated to the Shift Supervisor within 5 min; the Shift Supervisor called the maintenance-worker and the Turnaround Coordinator on the site. (5) The permissive was restored to the normal state; the LOTO isolation was documented on the site LOTO log per 29 CFR 1910.147; the near-miss was filed on the site's incident-tracking system per PSM Element 11. Result: (a) the near-miss triggered a root-cause meeting the next morning; (b) the site updated the LOTO procedure to require a DCS-permissive sign-off by Operations Console for any bypass associated with maintenance LOTO; (c) the maintenance-worker was retrained on the site LOTO procedure. Interviewers screen for Console Operator candidates who own the LOTO / permissive discipline, understand the PSM element numbers, and escalate near-misses without hesitation.

Q4. Why refinery / chemical / pharmaceutical operations rather than general manufacturing?culture

Honest answer that resonates. 'I like the intellectual rigor and the stakes. A refinery or chemical plant runs 24/7/365 with 300-800 control loops per unit; the operator is the primary defense against a runaway reaction, a runaway distillation column, or a compressor trip that cascades through the site. The PSM discipline (14 elements under 29 CFR 1910.119) is the framework that makes catastrophic events rare — but the operator's judgment on shift is what keeps it that way. Pay is real — Console Operator at a Marathon Petroleum, ExxonMobil, or Chevron refinery is $34-42/hr with USW / ICWUC pension and healthcare, and total earnings with shift differential and overtime typically clear $95-135k. Sr Operator / Lead is $42-52/hr with total earnings $115-160k. Long-term I want to move to Console Operator within 5 years and Sr Operator / Lead within 10, potentially Shift Supervisor at year 15. I've completed my AAS Process Technology from Lee College and my HAZWOPER 40-hr; I'm working on OSHA PSM Auditor certification and API 570 Piping Inspector.' Interviewers screen for candidates who understand the PSM framework and the OT / shift-differential economics — not who drift in from another manufacturing sector.

Q5. Where do you see your career in 5 years?closer

Show the ladder clearly. 'I'm at year 3 as an Outside Operator on the Crude Unit at a Marathon Petroleum Galveston Bay Refinery. Year 4-6 target: complete HAZWOPER 40-hr, OSHA 30 Petrochemical, and PSM familiarization; cross-train on the DCS console and take the Assistant Console Operator bid at year 4-5. Year 6-9 target: Console Operator at $34-42/hr with total earnings $95-135k including shift differential and overtime. Year 10-14: Sr Operator / Lead at $42-52/hr with total earnings $115-160k; take the Sr Operator bid when the seniority-and-qualification lists open. Year 15+: Shift Supervisor at $115-145k salaried with 12-18% bonus and LTIP eligibility. Long-term the fork is between staying bargaining-unit as Sr Operator with USW pension and healthcare vs moving salaried to Shift Supervisor / Operations Superintendent with LTIP and RSU vesting; the fork is typically decided at year 12-15 based on whether the operator completes the BS Chemical Engineering Technology through employer tuition support.' Interviewers screen for candidates who understand the concrete promotion criteria at the specific site.

Resume Template — Console Operator / Board Operator (5-11 yrs)

Copy these bullets into your resume as a starting point. Career Kit includes bullets for every level of the ladder.

Console Operator / Board Operator (5-11 yrs)

▸Console Operator on the Crude Atmospheric Distillation Unit (CDU) at a Marathon Petroleum Galveston Bay Refinery; owned 240 DCS control loops on the Honeywell Experion PKS platform across a 285,000 BPD crude tower.
▸Delivered a 32% reduction in operator-attributable unit trips over 24 months (from 6 to 2 in the prior comparison window) through structured alarm-response discipline and start-up-procedure adherence per PSM Element 4.
▸Executed 4 unit start-ups from planned turnaround in the last 5 years without environmental exceedance or safety incident; PSSR sign-off on all 4.
▸AAS Process Technology (Lee College) + HAZWOPER 40-hr + OSHA 30 Petrochemical + PSM Auditor Level I. USW Local. $38.20/hr base + $3.10/hr shift differential + $18k FY24 OT + USW pension + full healthcare + 401(k) match to 8%. Total FY24 earnings $128k.

What Gets You Rejected

✗No HAZWOPER 40-hr or lapsed HAZWOPER 8-hr annual refresher — 29 CFR 1910.120 disqualifier at any OSHA PSM facility.
✗History of unit trips or process-safety incidents attributed to operator error without documented corrective-action follow-through — the number-one screen at any refinery / chemical / pharmaceutical hiring loop.
✗Cannot describe the 14 PSM elements or cannot cite the specific PSM element related to a specific operator responsibility — signals candidate has been through the training without internalizing the framework.
✗Weak DCS-platform experience (Honeywell Experion, Emerson DeltaV, Yokogawa CENTUM, ABB 800xA) after 3+ years at a covered facility — signals candidate has been kept on the outside-operator bench.
✗History of alarm-flooding or alarm-normalization (silence-and-forget on nuisance alarms) — signals candidate has not internalized ISA 18.2 / IEC 62682 alarm-management discipline.
✗LOTO / permissive-bypass violations — 29 CFR 1910.147 and PSM Element 9 (Hot Work Permit) discipline is table stakes; violations create OSHA-inspection audit-trail exposure.
✗Attendance-policy violations — USW / ICWUC / Teamsters CBAs have written attendance-point systems, and repeat violations bar promotion regardless of technical competence.
✗No AAS Process Technology or 2-year technical credential after 5+ years in the seat with career ambition beyond Console Operator — the Sr Operator and Shift Supervisor track increasingly requires the AAS at Fortune-500 OSHA PSM employers.

Salary Negotiation Levers

✓OSHA PSM facility premium — the same operator seat at an OSHA PSM covered refinery / chemical / pharmaceutical facility pays 30-60% above the same seat at a general food / dairy processor; the premium reflects HAZWOPER, PSM familiarization, and the elevated safety-training investment.
✓Union representation — USW (which absorbed PACE), ICWUC (International Chemical Workers Union Council), Teamsters, and UFCW at many refineries and chemical plants typically deliver a 15-30% wage premium plus defined-benefit pension (still available at USW-refinery employers) or defined-contribution 401(k) with 6-10% employer match and full healthcare against non-union employers in the same metro.
✓Shift differential — 2nd-shift typically $1.50-3.00/hr; 3rd-shift and rotating typically $2.00-4.00/hr; weekend / continuous-operations differential often adds another $1-2/hr; total shift differential typically adds 8-15% to base earnings for continuous-operations Console Operators.
✓Overtime discipline — most USW / ICWUC CBAs pay 1.5x after 8 hrs / day and 40 hrs / week, 2x on Sundays and 6th consecutive day, 2.5x on holidays; total OT typically adds 20-35% to base earnings for high-seniority Console Operators (OT is heavily allocated by seniority in union plants).
✓Console Operator premium — union plants typically pay $4-7/hr above the base Outside Operator rate for the Console classification; Sr Operator premium $6-10/hr; Shift Supervisor premium (salaried) $15-30k above the Lead Operator equivalent.
✓Refinery-corridor metro premium — Houston Ship Channel / Gulf Coast / Golden Triangle / Chemical Alley (Freeport / Baytown / Beaumont / Port Arthur / Corpus Christi / Lake Charles / Baton Rouge / New Orleans / Pascagoula) pay 15-30% above the US median; Bay Area (Chevron Richmond, PBF Martinez), Delaware Valley (Phillips 66 Bayway, Monroe Energy Trainer), Puget Sound (BP Cherry Point, Marathon Anacortes) pay 20-40% above the US median but cost-of-living offsets most of the gain.
✓Turnaround overtime premium — refinery and chemical turnarounds every 3-6 years generate 6-14 weeks of elevated OT ($30-70k additional earnings) for operators on the turnaround crew; some sites pay a turnaround-completion bonus of $3-15k.
✓Sign-on bonus and relocation — Marathon Petroleum, ExxonMobil, Chevron, Valero, Phillips 66, and Dow routinely pay $5-25k sign-on and $8-25k relocation for Console Operator and Shift Supervisor hires from out-of-metro.
✓Tuition reimbursement — Section 127 caps at $5,250/yr federal tax-free; Fortune-500 refinery and chemical employers routinely top this up for AAS Process Technology and BS Chemical Engineering Technology at $12-25k/yr, and this is the practical path to the Sr Operator, Shift Supervisor, and Operations Superintendent track.
✓Safety-milestone and reliability bonuses — perfect-attendance annual bonuses $500-2,500; safety-milestone bonuses $500-3,000 per site-level milestone; reliability / on-stream-factor bonuses tied to unit-level uptime KPIs.

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Separating, Filtering, Clarifying, Precipitating, and Still Machine Setters, Operators, and Tenders Salary by State

Best Cities (cost-adjusted) →

Salary Map — Click a state for details

$36K

$109K■ No data

Top Paying States

Vertical line = national median. Click a state for full details.

State	Median	vs. National	Employment
Wyoming	$108,900	+111.0%	410
Nevada	$62,960	+22.0%	270
New Hampshire	$60,340	+16.9%	590
Wisconsin	$60,100	+16.5%	1,520
Virginia	$59,480	+15.2%	2,130
North Dakota	$59,390	+15.1%	270
Kentucky	$58,770	+13.9%	1,500
Louisiana	$58,640	+13.6%	770
New Jersey	$58,140	+12.7%	930
Arizona	$57,820	+12.0%	970

Showing 1–10 of 50

Separating, Filtering, Clarifying, Precipitating, and Still Machine Setters, Operators, and Tenders Salary by Metro Area

Metro Area	Median	vs. National
Syracuse, NY	$82,530	+59.9%
Vallejo, CA	$82,440	+59.7%
Atlanta-Sandy Springs-Roswell, GA	$80,140	+55.3%
Virginia Beach-Chesapeake-Norfolk, VA-NC	$76,350	+47.9%
Modesto, CA	$73,690	+42.8%
Hanford-Corcoran, CA	$66,310	+28.5%
Napa, CA	$64,000	+24.0%
Owensboro, KY	$63,700	+23.4%
San Francisco-Oakland-Fremont, CA	$62,320	+20.8%
Merced, CA	$61,920	+20.0%

Showing 1–10 of 190

Data Source: U.S. Bureau of Labor Statistics, Occupational Employment and Wage Statistics (OEWS). Data reflects the most recent annual survey.

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A separating, filtering, clarifying, precipitating, and still machine setters, operators, and tenders earning $51,610/year would need 1155 years to match Stephen Curry's NBA salary, or 1240 yearsto match Patrick Mahomes' NFL contract.

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