Unlocking energy efficiency: Empowering Sri Lanka’s climate efforts through Motor-driven System Optimization

As Sri Lanka aims to reduce its industrial greenhouse gas (GHG) emissions by seven per cent by 2030, its attention is turning to motor-driven systems. Industry is key to the country’s economic recovery, with 30 per cent of the workforce employed in the sector, which generated 27 per cent of GDP in 2023. Transitioning to sustainable and energy-saving practices is vital to future-proof industry and reach carbon reduction targets.

Through the United Nations Industrial Development Organization (UNIDO), 30 industrial workers are undergoing Motor-driven System Optimization (MSO) training, which is part of UNIDO’s broader Energy Systems Optimization (ESO) programme. Participants will learn how to operate motor systems in a more energy-efficient way, through both classroom sessions and digital simulations. The course, led by Energy Management and Motor-Driven Systems Expert Siraj Williams and Motor-Driven Systems Expert Prof. Anibal T. De Almeida, began in May 2023, is set to conclude in mid-March 2024 with a final examination.

Despite numerous improvements made over the years, motor-driven systems are still maintained and operated much the same way as they were 50 years ago. They are often run until they fail, and many operators lack the knowledge to gauge the health and efficiency of their equipment. Consequently, energy wastage, unscheduled downtime and the resulting costs are all too common. This is despite motor-driven systems accounting for 47 percent of worldwide energy consumption, and 70 per cent of industrial energy demand.

With motor systems underpinning so many processes – from compressed air generation to ventilation and the pumping of water – it’s essential that they’re run, maintained and operated with expertise. According to UNIDO’s findings, organizations adopting a holistic, system-wide approach to energy efficiency can achieve energy savings ranging from 10 to 50 per cent, whereas optimizing a single component will likely produce savings of just three to five per cent. A single leaking pipe or faulty compressor has the potential to compromise the performance of an entire motor-driven system, meaning each component must be selected with care, correctly sized, and operated with maximum efficiency. It is crucial to conduct a comprehensive evaluation of the entire system to ensure energy isn’t being wasted due to faults.

Senior electrical engineer at TeeJay Lanka PLC Supun Sandaruwan is a participant on the training programme, and is in charge of several energy-intensive heat treatment machines. “The MSO training showed me opportunities I could use to save energy by optimizing the motor systems in these machines, as well as reducing maximum demand as a large power consumer,” he said. “We have made significant progress in reducing the kilo-volt-ampere (kVA) consumption in our plant from 4000 kVA consumption per month to 3600 kVA by applying power factor correction practices of 0.98 or higher. This translates to substantial savings in electricity costs for the company.”

Participants at the MSO training hail from multiple key industries in Sri Lanka, from textile and rubber manufacturing to food production and packaging. All sectors represented use substantial amounts of energy in their production processes.

Production Manager at Finnpack Industries, W.K.A.A. Chaturanga, explained that the MSO training encourages participants to look beyond the individual motor and examine the system as a whole. “In our plant, where we extrude polythene film, we encountered a bottleneck when working with recycled materials,” he said. “There were blockages at the filtering stage which increased pressure and caused temperature spikes. Drawing on my MSO training knowledge, I assessed that the machine was operating at only 60 per cent efficiency. By replacing the nets and filters, increasing the filtering area and adjusting the barrel pressure and screw speed accordingly, we anticipate reaching an efficiency level of around 85 per cent.”

Since the start of the MSO training, S.M.P.S Samaraweera, a production engineer at Noritake Lanka Porcelain has been working with his team on an action plan to analyze and improve the energy efficiency of the ball mill used in ceramic production processes. “Using the tools and knowledge acquired through the training, I was able to conduct a thorough assessment of the system and determine that integrating a more compatible capacity inverter would not only significantly reduce energy consumption but also extend the lifespan of the motor and ball mill, while minimizing maintenance requirements.”

Echoing similar sentiments, Chaminda Hulangamuwa of CBL Plenty Foods (Pvt) Limited – one of Sri Lanka’s largest food manufacturing conglomerates – said: “We operate seven extruders, each powered by 75 hp motors, to produce cereal powder. Following the MSO training, I identified several opportunities to minimize energy wastage in our machines: integrating soft-starters, transitioning to direct coupling for transmission instead of belts, and introducing automation to reduce stoppages. By monitoring motor amperage, lubrication levels can automatically be adjusted, which decreases energy usage during high-amperage operation. The extruders account for 60 to 75 per cent of our total energy costs. I believe that with these measures in place, we can achieve a 20 per cent reduction in the energy consumption of these machines.”

Participants who successfully complete the programme will return to their organizations as UNIDO Certified MSO experts, ready to harness the significant untapped potential for energy efficiency in electric motor-driven systems at their facilities. The MSO training lays the foundation for more advanced programmes including Pump System Optimization (PSO) and Compressed-air System Optimization (CASO).