Key Responsibilities and Required Skills for Jet Plant Operator

🎯 Role Definition

The Jet Plant Operator operates and maintains jet fuel production, storage, and distribution equipment to ensure continuous, safe, and regulatory-compliant supply of aviation-grade fuel. The role requires real‑time process control (DCS/PLC/SCADA), routine equipment inspections, corrective maintenance coordination, fuel sampling and testing, precise inventory reconciliation, and strict adherence to environmental, health and safety (EHS) protocols. The operator supports shift handovers, executes planned start-ups and shutdowns, and escalates abnormal conditions promptly to minimize operational risk and product non‑conformance.

📈 Career Progression

Typical Career Path

Entry Point From:

Tank Farm Operator
Materials Handling Technician
Plant Maintenance Technician

Advancement To:

Senior Plant Operator / Lead Operator
Shift Supervisor / Operations Supervisor
Plant/Terminal Manager
Process Technician or Reliability Engineer

Lateral Moves:

Instrumentation & Controls Technician
Mechanical Maintenance Technician
HSE Specialist (Process Safety)

Core Responsibilities

Primary Functions

Monitor, control and optimize jet fuel production and distribution processes using distributed control systems (DCS), PLCs and SCADA, ensuring product meets Jet A / Jet A‑1 specification limits (flash point, density, freezing point, contamination) while maintaining target throughput and minimizing variability.
Conduct routine rounds and inspections of pumps, compressors, heat exchangers, filters, tanks, valves and blending skids; identify leaks, wear, abnormal vibration or temperature trends and initiate corrective action or maintenance work orders.
Execute safe and compliant hot and cold start-ups, shutdowns and emergency depressurization procedures for production units, storage farms and transfer systems in accordance with plant operating procedures and permit-to-work requirements.
Perform jet fuel sampling, on-site basic testing and chain-of-custody documentation; interpret laboratory results and coordinate with quality control to quarantine, blend or rework product that falls outside specification.
Operate and maintain fuel filtration, dehydration, blending and additive injection systems to deliver consistent product quality; adjust process parameters and flow paths to compensate for feed variability.
Manage tank and pipeline transfers including receipt of inbound shipments, meter reconciliation, gross/net volume accounting, pump sequencing and custody transfer documentation to ensure accurate inventory control and billing.
Respond immediately to alarms and process upsets; diagnose root causes using trend analysis, process instrumentation and control logic review, and coordinate rapid corrective maintenance with electricians, mechanics and engineers.
Execute preventive maintenance checks and assist maintenance teams during corrective repairs — perform basic mechanical tasks such as replacing seals, bearings, filters, and packing or performing alignment checks under supervision.
Maintain and calibrate critical instrumentation (pressure, level, temperature, flow meters) and verify integrity of safety systems such as emergency shutdowns (ESD), overpressure protection and flame/arrestor devices.
Comply with, enforce and lead by example on all HSE programs including confined space entry, hot work permits, LOTO (Lockout/Tagout), fire prevention, spill response, hazardous materials handling and PPE usage; report near‑misses and participate in investigations.
Execute fuel quality assurance and contamination control protocols: run petroleum hydrocarbon and water checks, verify cleanliness of hoses and filters, and follow preservation procedures for aviation fuel to prevent microbial growth or particulate contamination.
Maintain accurate shift logs, operational checklists, SOPs and handover reports; communicate process deviations, planned maintenance and safety observations to incoming shift and operations management.
Coordinate and supervise contractors and third-party vendors performing maintenance, inspections or turnaround activities; validate permits, conduct pre‑job briefings and ensure contractor compliance with site safety and quality standards.
Lead and participate in root cause analyses (RCA) and continuous improvement activities (Kaizen, 5S, MOC) to reduce downtime, improve reliability and optimize energy consumption within fuel production and handling systems.
Implement environmental compliance practices to control emissions, manage wastewater, and handle fuel spills; maintain records required for regulatory reporting and cooperate with environmental audits.
Ensure proper handling and storage of additives, solvents and hazardous materials; verify SDS compliance and proper labeling and storage segregation.
Troubleshoot pump and compressor performance issues, including cavitation, seal failures, and bearing wear; adjust mechanical seals, packing, and lubrication systems as part of corrective measures.
Operate and maintain plant utilities that support jet fuel operations — steam boilers, air compressors, cooling water circuits and electrical distribution — to sustain uninterrupted production.
Execute scheduled turnarounds, outages and equipment changeovers: plan scope with maintenance and reliability teams, perform isolation and testing tasks, and validate readiness for restart.
Maintain a culture of continuous learning by attending training on process safety management, fuel specification updates, instrumentation, and emergency response drills.
Perform custody transfer testing and measurement validation for metering systems, flow computers and prover calibrations to maintain accuracy of delivered volumes and invoicing integrity.
Support digital monitoring initiatives by contributing operator knowledge to analytics teams, validating alerts, and helping refine predictive maintenance models and alarm rationalization.

Secondary Functions

Assist in fuel logistics coordination with operations planners and third‑party carriers to schedule shipments and optimize storage utilization.
Participate in cross‑functional meetings with quality, maintenance and safety to align priorities during shifts and plant-wide campaigns.
Support inventory reconciliation, stock audits and fiscal reporting for fuel movements and residuals.
Train and mentor junior operators and temporary staff on standard operating procedures, safety practices and emergency response expectations.

Required Skills & Competencies

Hard Skills (Technical)

Proficient operation of DCS / PLC / SCADA systems (e.g., Honeywell, Emerson DeltaV, Siemens, Allen‑Bradley) for real‑time process control and alarm management.
Strong understanding of petroleum refining and aviation fuel handling processes: distillation, blending, dehydration, filtration, and additive dosing for Jet A / Jet A‑1.
Hands‑on experience with centrifugal pumps, positive displacement pumps, rotary screw compressors, heat exchangers and associated mechanical systems.
Competence in conducting fuel sampling, custody transfer procedures, chain‑of‑custody, and interpreting laboratory test results (ASTM D1655, D4052, D2386 and related tests).
Proficiency with instrumentation: pressure, level, temperature, flow measurement devices and field calibration techniques.
Familiarity with HSE and regulatory frameworks: OSHA, EPA, MARPOL (where relevant), ATEX and process safety management (PSM).
Practical knowledge of lockout/tagout (LOTO), confined space entry, hot work permits, spill response and hazardous materials management.
Ability to perform basic mechanical troubleshooting and preventive maintenance tasks, write clear work orders and prioritize corrective actions.
Experience with custody transfer metering, flow computer configuration and metrology fundamentals for accurate fuel reconciliation.
Competence using CMMS (e.g., SAP PM, Maximo) for maintenance planning, work order execution and inventory control.
Working knowledge of permits, documentation control, and electronic/logbook record keeping practices.
Data literacy: ability to interpret process trends, run basic root cause analysis (RCA), and support continuous improvement with quantitative input.

Soft Skills

Strong attention to detail and commitment to following checklists, SOPs and safety rules consistently.
Clear communicator able to produce concise shift logs, handovers and written incident reports.
Decisive under pressure with the ability to prioritize safety and quickly escalate abnormal situations.
Collaborative team player who coordinates effectively with maintenance, quality, logistics and management.
Continuous improvement mindset with curiosity to identify inefficiencies and contribute to reliability projects.
Adaptability to rotating shifts, on‑call duties and changing operational priorities.
Good observational and diagnostic thinking for detecting subtle equipment or process anomalies.
Leadership potential to mentor junior staff and lead small teams during turnarounds or critical events.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED; demonstrated experience in plant operations or fuel handling.

Preferred Education:

Technical diploma, Associate degree or certifications in Process Technology, Mechanical Technology, Instrumentation, Chemical Engineering Technology or related field.

Relevant Fields of Study:

Process Technology / Chemical Process Operations
Mechanical Engineering Technology
Instrumentation & Control
Petroleum Technology
Environmental Health & Safety

Experience Requirements

Typical Experience Range:

2–5 years of hands‑on experience in refinery operations, terminal/plant fuel handling, or a process manufacturing environment.

Preferred:

5+ years operating or supervising jet fuel, aviation fuel production, refinery units, chemical plants, or bulk fuel terminals with demonstrated competency in process control, fuel quality, and HSE compliance.
Certifications preferred: HAZWOPER, Confined Space Entry, CPR/First Aid, LOTO certified, and operator training specific to DCS/PLC platforms.