New training and education initiatives in the lubricants industry

Citation

(1999), "New training and education initiatives in the lubricants industry", Industrial Lubrication and Tribology, Vol. 51 No. 4. https://doi.org/10.1108/ilt.1999.01851daf.001

New training and education initiatives in the lubricants industry

New training and education initiatives in the lubricants industry

Keywords British Lubricants Federation, Training, NVQ

The British Lubricants Federation, which has already now successfully implemented its National Vocational Qualification (Level 2) for Lubricants Plant Process Operations, is embarking on two further main training initiatives which will play an important part in raising knowledge standards for all levels of staff working in the lubricants industry. These two additional training programmes are:

1. 1.

   Certificate of Lubricants Competence (CLC).

2. 2.

   Advanced Lubrication Training Programme (ALTP).

NVQ update

The first two groups of candidates to be awarded their NVQ qualification in Lubricant Plant Operations are based at Castrol's Hyde plant, which manufactures industrial lubricants, and at Mobil's Birkenhead plant, which manufactures a comprehensive range of lubricants for the BP/Mobil Joint Venture. In addition, a number of operators from Castrol's automotive lubricant plant at Stanlow are expected to gain the qualification in the near future.

These awards represent the culmination of much effort over a number of years by a dedicated team drawn from the BLF membership, chaired and administrated by the BLF Technical Officer, David Margaroni, who is now acting for City & Guilds as an external verifier for this standard.

The essential stages in the development may be summarised as follows:

• •

  initial feasibility study;

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  identification of partner body (The Petroleum Employers Skills Council, now the Petroleum Industry National Training Organisation);

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  identification of team members;

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  compiling the preliminary standard;

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  application for a government grant from the Department of Further Education & Employment;

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  interviewing and subsequent appointment of a consultant;

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  further meetings of the group to finalise the initial NVQ according to the recommendations of the consultant;

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  selection of suitable organisations to critically evaluate the NVQ (field trial);

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  amendment of the NVQ to incorporate feedback from the field trial;

• •

  submission of the amended NVQ to City & Guilds;

• •

  amendment of the NVQ to incorporate feedback from City & Guilds;

• •

  submission of the amended NVQ to NCVQ (now the QCA, Qualifications and Curriculum Authority);

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  amendment of the NVQ to incorporate feedback from Qualifications and Curriculum Authority;

• •

  identification of three member companies to become practically involved in a limited pilot launch (Castrol, Mobil and Polartech);

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  selection of a suitable establishment to act as a centre for the pilot launch (Wirral Metropolitan College);

• •

  training of an external verifier (D. Margaroni) to act for City & Guilds;

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  approval of Wirral College by City & Guilds;

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  further meetings of the implementation group to monitor progress;

• •

  approval of initial candidate portfolios by City & Guilds external verifier;

Now that the NVQ has been satisfactorily established, with an operating centre based in the Wirral, it has been necessary to identify and establish other centres throughout the country. Two further centres have now been set up to serve the needs of companies on a suitable localised basis. Midland Oak Skills and Technology Ltd (MOST), based at Tipton, in the West Midlands, UK and Kirkdale Industrial Training Services Ltd (KITS) based at Brighouse, Yorkshire, UK have been approved to operate the Lubricants Plant Operations NVQ.

The unit and element structure of the standard is as follows:

Unit 1. Prepare for lubricants processing operation

• •

  Element 1.1 Prepare working area and equipment.

• •

  Element 1.2 Obtain and prepare materials.

Unit 2. Perform lubricants processing operation

• •

  Element 2.1 Charge vessels.

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  Element 2.1 Carry out operation.

Unit 3. Maintain health, safety and environment in lubricants production

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  Element 3.1 Apply safe working practices.

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  Element 3.2 Observe emergency procedures.

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  Element 3.3 Observe environmental requirements.

Unit 4. Establish and maintain effective working relationships

• •

  Element 4.1 Establish and maintain effective working relationships with colleagues.

• •

  Element 4.2 Establish and maintain effective working relationship with immediate manager.

Unit 5. Comply with Lubricants Production Quality System

• •

  Element 5.1 Operate quality system.

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  Element 5.2 Perform quality control checks.

BLF Certificate of Lubricants Competence (CLC)

The Federation launched this new training initiative this year, with the first module held on 25 February 1999. The course is aimed primarily at new entrants but equally it will be appropriate for all non-technical personnel within member companies.

The intention is that course material will be provided on a modular basis. The course consists of nine separate one-day training sessions, each linked to the next subject being covered. The overall aim is to provide a complete "beginners" cradle to grave coverage, i.e. exploration to final disposal of the used product, on the subject of lubricants and lubrication. BLF member company personnel will in the main be providing the speakers for each topic. The course is designed to offer the basics of what lubricants are, how they are formulated, the different types being offered to users, why there are different requirements and most importantly the safety, health and environmental issues lubricants and greases create.

Subject areas covered by the course material are as follows:

1. Exploration and refiningSubject-matterCovering the basic geology and formation of oil bearing strata, the geographical distribution of known oil reserves, the history of exploration, the formation of the major oil companies and a brief Industry history, refining and the progression of refinery technology from initial techniques through to current trends to ID technology.

2. Base oil types and characteristicsSubject-matterConcentrating on the way refining and crude oil origin define the characteristics and properties of the resulting base oil and their subsequent best use. Covering areas such as pour point, volatility, oxidation stability and the advantages and disadvantages of various properties to different types of blended lubricants.

3. Basic tribologySubject-matterThis course element is designed to give a basic understanding of concepts such as elastohydrodynamic lubrication, boundary lubrication and extreme pressure conditions, perhaps extending to cover anti-wear, fretting corrosion and tool life in the context of the later course elements.

4. Lubricant additivesSubject-matterAn explanation of the basic additives used in the various categories of lubricants, their chemistry at a simplistic level, their function and their performance in respect of the tribology covered in the previous element. This should not only relate to additives used in automotive and basic Industrial lubricants but should draw parallels with speciality areas such as grease and metalworking.

5. Automotive lubricantsSubject-matterAn enormous topic covering not only engine oils for both gasoline and diesel engines but transmission and hydraulic applications in addition. Following on from the additive element this session should highlight the application of the different additive chemistries, relating both types and treat rates to levels of performance and specifications. The history of specifications up to and including the latest ACEA performance levels should be covered.

6. Industrial lubricantsSubject-matterA comprehensive look at hydraulic and circulatory, gear oils, open gears, slideway oils etc. including particularly the importance of viscosity and additive selection, and relating strongly to both the tribology and additive elements. Basic guidance on selection of the correct lubricant and the importance of the lubrication survey and rationalisation to be included.

7. GreasesSubject-matterA science in itself, the sphere of use of grease, its different manufacturing considerations, additive types and the basic terminologies of consistency, penetration, drop point etc. should all be covered.

8. MetalworkingSubject-matterMetalworking fluids have become an increasingly important part of the product portfolio of most lubricant companies. This element should explore the basic differences in chemistry and application between neat and watermix fluids, should explain emulsions and emulsifiers at a simplistic level, should cover the additive technology and different tribological implications when related to the previous elements and should give a thumbnail sketch of the industries which form the potential customer base.

9. Health, safety and environmentalSubject-matterCovering the evolution of the health and safety of ingredients, lead, sodium nitrite etc. in various categories of lubricants moving on to later issues such as biocides, middle order metals and discussing environmental legislation and trends.

During this session other aspects are also covered relating to biodegradable lubricants, vegetable and ester basestocks and fluids used in the environment.

It is currently envisaged that there would then be a final session, giving ten segments in total which would review the elements covered, answer questions and award the BLF Certificate of Lubricant Competence, for those who reach a required standard of competence in a short examination.

BLF Advanced Lubrication Training Programme (ALTP)

The Federation is also launching a programme of one-day courses to be known as the BLF Advanced Lubrication Training Programme. The first four modules will be held this year commencing from July. Pathmaster Marketing's David Whitby will be the organiser and provider of this new venture. ALTP will comprise ten one-day modules provided over a two-year period, in a similar format to the basic training provided by the BLF Certificate of Lubricants Competence (CLC).

A synopsis of the ten one-day modules content is shown below:

Module 1: automotive lubricants

• •

  ACEA, SAE and ILSAC specifications for engine oils.

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  Developments in vehicle design and operation, and their effects on lubricants.

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  Heavy duty diesel engine drain intervals and lubricant performance.

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  The European auto-oil programme, and the influence of fuels on engine oil performance.

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  The chemistry of automotive engine, gear and transmission oils.

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  Lubrication of LNG, LPG, fuel cell, electric and hybrid vehicles.

Module 2: industrial lubricants

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  Developments and trends in gear, bearing and circulating oils.

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  Developments and trends in hydraulic and turbine systems and fluids.

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  Developments and trends in compressors and compressor oils.

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  Developments and trends in transformer, electrical, switchgear and cable oils.

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  Developments and trends in textile, food grade and white oils.

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  Industrial lubricant analysis and condition monitoring of industrial equipment.

Module 3: metalworking fluids

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  Advances in production engineering and their effects on lubricant requirements.

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  Developments and trends in machining fluids.

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  Monitoring and controlling metalworking fluids in practice.

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  Metalworking fluid misting and its control.

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  Developments and trends in rolling, drawing and casting fluids and pastes.

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  Developments and trends in heat treatment fluids.

Module 4: greases and solid lubricants

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  Types, properties and applications of greases and solid lubricants.

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  Developments and trends in automotive greases.

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  Developments and trends in industrial greases.

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  Developments and trends in wire rope, chainbar and anti-seize lubricants.

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  Railroad, marine and mining greases and solid lubricants.

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  Solid lubricants and pastes for consumer applications.

Module 5: synthetic and high performance lubricants

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  Types of synthetic fluids and their performance.

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  Group I to V base oils and the future of base oil interchangeability.

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  Synthetic and VHVI-based automotive lubricants.

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  Synthetic and VHVI-based industrial lubricants.

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  Markets in Europe, North America and Asia for high performance lubricants.

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  Performance comparisons for synthetic and mineral oil lubricants.

Module 6: lubricants manufacturing and distribution

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  Developments and trends in base oil refining.

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  Comparative economics of base oil and synthetic fluid production.

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  The additive manufacturing business.

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  Developments and trends in lubricant blending and packaging.

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  Global supply and distribution of base oils and lubricants.

Module 7: health and safety issues for lubricants

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  Toxicity and eco-toxicity of base oils, additives and formulated lubricants.

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  Lubricant packaging and safety labelling regulations and practices.

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  Industrial hygiene in the manufacture, use and disposal of lubricants.

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  Health and safety issues associated with aromatics, chlorinated paraffins, amines, phosphorus and heavy metals in lubricants.

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  Best practices with lubricants for a healthy working environment.

Module 8: environmental issues for lubricants

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  Customer and legislative pressures for environmental best practice.

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  Life cycle analysis.

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  Biodegradable and low toxicity lubricants.

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  Methods for determining the biodegradability of lubricants.

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  Environmentally friendly lubricants and environmental labelling.

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  Environmental management systems; EMAS, 1S0 14001, BS 7750.

Module 9: used lubricant collection, disposal, recycling and re-refining

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  Used lubricant labelling and transport regulations in the UK and Europe.

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  Recovery methods, regulations and economics.

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  Disposal methods for waste lubricants.

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  Methods for re-refining used lubricants.

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  Comparative economics of disposal, re-refining and recycling.

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  International practice: Europe, North America, Asia and other regions.

Module 10: trends and developments in lubricants business management

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  Developments and trends in total fluid management.

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  Developments and trends in key account management.

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  Lubrication surveys and methods for selecting the correct lubricant(s).

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  Methods of competitor analysis.

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  Lubricants distribution and supply logistics.

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  Economic evaluation of lubricants technical service.