Washington State Ferries customers enjoyed a 99.87% trip completion rate in 2005. That is the actual number of scheduled trips that were completed, not including weather or tidal cancellations; and includes those trips that WSF was able to complete by replacing one vessel with another.

The Lifecycle Model

To keep our service so dependable, WSF’s Maintenance Department plans vessel maintenance and preservation work years in advance. This advanced scheduling system helps our Maintenance Department stay ahead of problems and is the reason for WSF’s high trip completion rate.

The Lifecycle Model involves scheduling “vital” equipment and parts for maintenance according to their useful lifespan. Vessel parts are classified into two categories – “vital” or “other.” Vital parts are those designated by the U.S. Coast Guard as vital to the protection of people, the environment, and the vessel. Other parts of the vessel may be important, but not “vital” as defined by the Coast Guard.

Every piece of equipment and every part have their own defined lifecycle, which is closely tracked and then scheduled in advance to either be replaced or preserved according to its lifecycle schedule. By doing this, the ferry system can allocate its resources in a way that makes sense for the entire system and keeps our operation running smoothly.

Equipment Maintenance is a Shared Responsibility

The responsibility of maintaining a vessel is shared among the vessel’s engine room crew, machinists at our Eagle Harbor maintenance facility, and contracted shipyards. The engine crew monitors and maintains the ferry’s propulsion system and auxiliary machinery; performs planned maintenance procedures; and maintains virtually every piece of equipment onboard the ferry. Many of these tasks are performed while the vessel is underway. Crews use nighttime hours to accomplish heavier repair and maintenance functions. This is what is known as “basic” vessel maintenance.

“Intermediate” vessel maintenance includes activities that require removing the vessel from service. Most intermediate maintenance activities are accomplished at the Eagle Harbor maintenance facility or at contracted shipyards. Often this work requires a shore-based infrastructure that is not available aboard ship. Examples of this maintenance include rebuilding engines, hydraulic component overhauls, and upholstery repair.

Workers providing intermediate vessel maintenance for the ferry system had their work cut out for them in 2005 – and they delivered.

In 2005 intermediate maintenance was done on several vessels. The work included engine overhauls, safety and security upgrades, ADA improvements, interior refurbishments, and more.

M/V WALLA WALLA
Vessel Class: Jumbo Class
Year Built: 1972
Usual Route(s): Replacement vessel

The largest project in 2005, most customers have ridden the “Wally” at one time or another. This vessel usually fills in on various ferry routes up and down Puget Sound to replace vessels that need emergency repair, annual inspections, or scheduled maintenance. According to the Lifecycle Model, the Walla Walla was due for significant preservation and maintenance work when she went into Everett Shipyard at the end of March 2005. (In 2003, the WALLA WALLA received four new engines; but her 30+-year old electronics and propulsion controls needed upgrading to keep her going strong.) In addition to the new engine propulsion control system, she also received a new emergency generator, a new exhaust system; a new fuel system with overflow prevention; a replacement emergency power battery charging system; modifications to the vessel electrical systems; and a state-of-the-art alarm and monitoring system. The engine and propulsion motors are now good for about another 40 years.

The vessel’s interior also received a much-needed refurbishment, and the pilothouse was equipped with all new controls, steering gears, searchlights, and new satellite compass. The vessel was also equipped with security upgrades, including surveillance hardware and access controls.

ADA improvements included new guardrails, accessible tables and drinking fountains, ramp slope and threshold improvements, and Braille signage. And, of course, one of the most notable additions and improvements is the new elevator.

M/V CHELAN
Vessel Class: Issaquah Class
Year Built: 1981
Usual Route(s): Anacortes/San Juans/Sidney, B.C.; Fauntleroy/Vashon/Southworth

The M/V CHELAN is now set to sail the international waters of the Strait of Juan de Fuca to take customers to Sidney, B.C. In 2005, the vessel was brought up to SOLAS (Safety of Life at Sea) standards for international service.

“SOLAS’ing” a vessel is no small task. The International Maritime Organization sets the standards that a vessel must meet to achieve SOLAS status and sail international waters. For vessels in the United States, the Coast Guard inspects the vessels to ensure all requirements and approves them for service.

First, a voyage data recorder is installed. Similar to the “black box” in airplanes, it records important information while the vessel is in service. Every system (steering, engine, propulsion, etc) feeds information to the data recorder so that a complete record is kept.

Bringing a vessel up to SOLAS standards also includes installing a fire protection system, including an alarm system that monitors all spaces on the vessel, fire doors, a passenger cabin sprinkler system, an upgraded ventilation system, and upgraded “A60”-coded insulation. A60 is a code that is used to classify materials that are able to withstand fire for 60 minutes. The vessel’s floor and bulkhead are also made to A60 code.

The vessel also gets extra emergency life rafts, watertight doors, and of course a new emergency generator to support all these new systems.

In addition to the SOLAS upgrades, the CHELAN also received new main engines, ship service generators, and new interior furnishings.

KALEETAN
Vessel Class: Super Class
Year Built: 1967
Usual Route(s): Seattle/Bremerton; Anacortes/San Juan Islands

Work actually began on the M/V KALEETAN in 2004, and was finished on February 11, 2005, with a commemorative ride from Foss Shipyard through the Ballard Locks to Colman Dock (Pier 52) in Seattle. The vessel received a new elevator and other ADA improvements, new ship service generators, new main switchboard, and security system upgrades.

YAKIMA
Vessel Class: Super Class
Year Built: 1967
Usual Route(s): Fauntleroy/Vashon/Southworth; Anacortes/San Juan Islands

Shortly after the KALEETAN left the shipyard, the M/V YAKIMA went in. The vessel received the same treatment as her sister ship, including a shiny new elevator and other ADA improvements, new ship service generators, new main switchboard, and security system upgrades.

M/V HYAK
Vessel Class: Super Class
Year Built: 1967
Usual Route(s): Seattle/Bremerton; Anacortes/San Juan Islands

The M/V HYAK is slated to return to service on Feb. 17, 2006, when she goes to the San Juan Islands to relieve the M/V KALEETAN.

The work done on the HYAK is an example of ways that WSF tries to address vessel maintenance needs while minimizing cost. Rather than receiving all new parts, many of the vessel’s old systems were replaced with parts from other vessels that had been refurbished or completely rebuilt and were good as new, but without the new price tag. The HYAK received four refurbished engines that were rebuilt by Marine Systems, Inc. at Todd shipyard. Three of the engines came from the M/V SPOKANE, and one from the M/V WALLA WALLA. The HYAK’s old-model engines had logged over 260,000 hours. She was the last vessel in WSF’s fleet to have the old model replaced.

The ship service generators, which had been overhauled at our Eagle Harbor maintenance facility, came from the KALEETAN, and the vital generator was replaced. The engine room’s alarm and monitoring system was modified so that it could be upgraded easily if needed, and the propulsion generators were cleaned.

The pilothouse got new radar, navigational equipment, and searchlights. Windows in the passenger cabin were replaced, and approximately 1000 square feet of the decking was repaired, the interior was professionally cleaned and damaged upholstery was replaced.

The vessel received the standard security system upgrades, including surveillance and access controls.

The HYAK was the last in the lineup of vessels to receive an elevator in 2005. She also received other small but modernizing features, such as self-illuminating Exit signs that will work even when there is no power to the vessel.

M/V KITSAP
Vessel Class: Issaquah Class
Year Built: 1980
Usual Route(s): Seattle/Bremerton; Fauntleroy/Vashon/Southworth

The M/V KITSAP received new Control Pitch Propellers (CPP) five years ago. In 2005, the CPP were inspected and approved for several more years of service. The vessel also received additional keel coolers for the ship service generators, and security system upgrades.

This work was done while the vessel was in its dry dock period. The Coast Guard requires that vessels receive dry dock inspections and/or maintenance twice in five years time. In addition to vessel preservation work in 2005, WSF also completed these Coast-Guard required inspections for many vessels last year.

Examples of dry dock work include painting the underwater hull, inspecting propellers and rudder, and inspecting sea valves.

The following vessels received dry dock inspections in 2005:

M/V Sealth
M/V Elwha
M/V Klahowya
M/V Evergreen State
M/V Tillikum
M/V Quinault
M/V Skagit
M/V Kalama

Washington State Ferries thanks our maintenance staff, machinists, engine crews, port engineers, and shipyard workers who worked hard to keep us up to date, safe, and reliable in 2005.