50MW project enters major turbine installation phase as tower erection gets underway

HayWind One Limited, the wind energy arm of Hayleys Fentons Limited, has marked a major milestone in the development of its 50MW Mannar Wind Farm, with turbine installation now in full swing and the first two 5MW wind turbines fully erected. The milestone sets the pace for the continuous installation of all ten turbines across the utility-scale project.

Each complete wind turbine reaches an impressive tip height of approximately 186.5 metres. The structure comprises a 110-metre tower assembled in four sections anchored to a heavy-duty concrete foundation reinforced with piles, an anchor cage, foundation bolts, and a high-strength grout layer. Mounted atop the tower is the nacelle, housing the main bearing, drive shaft, gearbox, generator, and an active yaw system to keep the rotor aligned with prevailing winds fitted with the hub and three 76.5-metre rotor blades. Given Mannar’s coastal conditions, all turbine components are equipped with specialised marine-grade anti-corrosion coatings and filtration systems.

The heavy lifting operations are carried out using a massive 900-tonne crawler crane, the largest ever deployed for a wind energy project in Sri Lanka supplied by Hayleys Advantis Limited in partnership with Sarans India. Prior to positioning the crane, engineering teams executed extensive ground stabilization, including aggregate base course preparation, soil compaction, and rigorous load-bearing tests to ensure platform safety.

Hasith Prematillake, Managing Director of Hayleys Fentons Limited, said: “Seeing our initial turbines fully erected in Mannar is a defining milestone for HayWind and a clear testament to what our engineering capabilities can achieve. Executing installations of this sheer scale requires meticulous planning, seamless cross-functional coordination, and high-calibre technical expertise. With the first turbines now standing tall, our teams have established strong operational momentum to deliver the remaining units.”

Roshane Perera, Deputy Managing Director – Energy of Hayleys Fentons Limited, added: “Turbine erection at this scale demands uncompromising safety standards, technical competence, and disciplined execution. Our engineers, site supervisors, and technical crews are GWO-certified (Global Wind Organisation), ensuring all operations strictly adhere to globally benchmarked protocols for wind energy construction.”

Prashantha Amarasinghe, Chief Operating Officer of HayWind One Limited, said: “Each lift is executed around dynamic ground and atmospheric conditions, strictly limited to wind speeds of 9.8 metres per second or below in compliance with OEM parameters. Ground stability and wind profiles are validated prior to every lift. Heavy-duty taglines ensure lateral control of each section during hoisting, complemented by real-time visual wind indicators to maintain precision.”

Upon completion, the Mannar Wind Farm will comprise ten 5MW turbines delivering an aggregate capacity of 50MW. The plant is projected to supply approximately 207 million units (kWh) of clean electricity annually to the national grid under a 20-year Power Purchase Agreement (PPA), saving Sri Lanka an estimated LKR 100 billion in foreign exchange on fossil fuel imports over its operating lifecycle.

With turbine installation advancing swiftly across the site, HayWind One remains firmly on schedule for commissioning and grid energisation by December 2026, marking another landmark stride in Sri Lanka’s clean energy transition.

Heavy lifting operations underway as the HayWind nacelle is positioned atop the tower at the Mannar site.

A fully assembled 5MW HayWind turbine standing tall against the Mannar coastline as the project advances toward full commissioning.