Cover Story: Mixed Parts

Mixed Parts

New hybrid-electric ferries provide a bridge to zero emissions.

By Bruce Buls, Editor-at-Large

On Jan. 23, 2020, Washington state Gov. Jay Inslee laid down the law: The burning of fossil fuels to power the state’s vessels, vehicles and facilities must be signi cantly reduced or eliminated. It’s called Executive Order 20-01 — “State Ef ciency and Environmental Performance.” In it, he “hereby orders” that, among other things, “The Secretary of the Department of Transportation shall ensure that the Washington State Ferry (WSF) system begins the transition to a zero-carbon-emission ferry eet, including the accelerated adoption of both ferry electri cation and operational improvements that will conserve energy and cut fuel use.” The target date is 2050.

OK then. For a eet of 21 car ferries that burn 19 million gals. of diesel per year, that’s a tall order. Not long ago, WSF had been contemplating a transition to natural gas-powered ferries as a cleaner and less expensive alternative to diesel, but the executive order put an end to that. Now it’s electri cation all the way. Or, at least, hybrid-electri cation for starters.

For ferries, going electric is a trend all over the world, led by Scandanavia, so WSF will have a lot of company, including two other Paci c Northwest operators.

In Canada, BC Ferries now has six Island-class batteryhybrid-electric car ferries, and to the west, across Puget Sound, Kitsap Transit has one hybrid-electric passenger boat and is preparing to build an all-electric sister vessel.

In July, WSF issued a request for information (RFI) prior to putting out a request for proposals this fall for the design and construction of ve hybrid-electric Olympic-class ferries, with the rst to be delivered by June 2027 and the fth by December 2031. According to the RFI, over the next 20 years, WSF intends to also convert six ferries, including

Washington State Ferries

The Wenatchee is one of three Jumbo Mark 11 ferries, Washington State Ferries’ largest, that is going to be retrofi tted with hybrid electric propulsion

three Jumbo Mark IIs, from diesel to hybrid electric and build a total of 16 new hybrid electric boats. Doing so, WSF said, will reduce the ferry system’s greenhouse gas emissions by 76% and toxic pollutants by 59% by about 2040. Total cost is estimated at almost $4 billion.

BATTERY CHARGERS

The new hybrid-electric Olympicclass boats will have a capacity of 144 cars and 1,500 passengers. According

All six battery-hybrid-electric Island-class ferries have arrived in BC. The ferries carry 47 vehicles and are double-ended for easy loading and unloading. The boats also feature wide vehicle lanes, dedicated pedestrian paths, and bicycle parking

to the RFI, the propulsion will be “hybrid battery-diesel electric with an automated charging system.” In addition, the “primary source of energy will be shore-based electricity to charge the onboard batteries, with diesel generators providing additional and/or backup energy.”

In other words, the new boats must have plug-in battery replenishment, which means establishing shoreside rapid charging systems capable of “full battery charging during a 20-minute dwell time at each terminal.”

Again, a tall order. David Sowers, WSF’s director for terminal engineering, said in a video interview that “the connection between the vessel and the terminal is really key to making the whole thing work.”

WSF plans to provide electric charging at 16 of its 19 terminals, some of which are in the middle of urban areas and some of which are on remote islands. “Currently there are not enough megawatts to charge up a boat,” said Sowers, “we need to work with the electric utilities to bring more power to the terminals.”

Nicole McIntosh, a WSF terminal engineer for 25 years, suggested putting more of the electrical interface infrastructure on the boats to avoid permitting problems for over-water electrical infrastructure shoreside. With that concept in mind, current plans envision a robotic charging arm coming from the vessel to a shoreside power connection.

Even so, getting enough electricity to the 16 charging terminals is a “real challenge because some of these utility companies don’t have the infrastructure yet to help us achieve these goals,” said Sowers. “We don’t want surges in the system and have all the lights in Seattle dim when a boat plugs in.” Still, the boat’s batteries will need an uninterrupted ow of electricity for 20-25 minutes to recharge the boat.

One solution to the charging challenge is shoreside buffer batteries that can be charged overnight or during periods of lower demand on the grid. “Shoreside batteries are being used in case there is not suf cient power available on the dock side,” said Henk Grunstra, product director for Damen Ferries in the Netherlands. Damen designed and built the Island-class ferries for BC Ferries. These were built as hybrid-electric with the expectation of becoming all-electric as soon as possible. “The boats are expected to operate for 40 to 50 years,” he said, “so it’s a no-brainer to go with electricity as soon as you can. It’s de nitely cheaper than conventional diesel propulsion.”

Getting the necessary shore power is proving to be the greater chal-

A rendering of the proposed robotic charging system to be installed on WSF’s hybridelectric ferries.

lenge of crossing the bridge to fully battery-electric. Damen recently built and delivered a pair of all-electric car ferries for operators in Ontario for Great Lakes routes, but the shoreside infrastructure is not yet in place for charging so the boats are not in service. “Apparently it’s much quicker to build a vessel then to change the quay side,” said Grunstra.

ISLAND-CLASS FERRIES

Meanwhile, the Island-class ferries are operating on gensets and batteries, providing “clean, quiet and ef cient hybrid battery-electric” propulsion, said Ed Hooper, BC Ferries’ executive director of shipbuilding. “At an economical cruising speed of up to 12 knots, the vessel typically operates with one diesel generator running together with the batteries to provide power.”

Economical cruising with battery power not only reduces emissions, it also translates into a reduction of generator engine maintenance and less frequent genset overhauls. The batteries’ life expectancy is between eight and 10 years, “depending on a number of factors, which are applicable to all batteries,” said Hooper.

The 266'×55' Island-class ferries were built at Damen’s shipyard in Romania. Each vessel has a pair of

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1,500-kW generators and an 800-kWh bank of Corvus lithium-ion batteries. But getting shoreside power established is still a work in progress.

“We have completed preliminary plans for upgrading the shore-based infrastructure to allow for plug-in/ recharge-from-shore capability,” said Hooper. BC Ferries is still looking for government grants to help offset the costs but “no timeframe has been nalized for the shore upgrades.”

Kitsap County, across Puget Sound from Seattle, currently operates a eet of 10 passenger ferries that range from high-speed, low-wake catamarans to a 100-year-old wooden monohull. It also owns and operates the Waterman, a 150-passenger aluminum catamaran with hybrid-electric propulsion. Designed by Glosten in Seattle and built a few years ago by All American Marine in Bellingham, the Waterman’s power package includes two 400-hp Cummins QSL9 engines with variable speed generators and two 40-kWh racks of XALT lithium ion batteries.

The entire system is tied together with BAE Systems’ HybriGen software that controls the combination of battery and generator power and integrates the electric drive motors, as well as the house load. Ray Scott, Kitsap Transit’s marine services director, said the operators can force the generators

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to be on or off, but “in our opinion it’s better for the system to do what it wants rather than force something it doesn’t want to do.”

What it wants to do is monitor battery capacity and have a generator kick in when the meter hits 25%. When the charge level is back at 85%, the generator(s) shut down. “The generators also will come on if we ask for 615 rpm or more to make sure we do not draw the batteries down too fast. That way they can keep the charge up while using full power,” said Scott.

Kelly Greenwood, one of the captains that operate the Waterman, said she likes using the system. “But it de nitely took a little while to get used to it, especially when the engines kick off when you’re underway. Hearing your engines die while coming into a dock is generally not a great thing.”

The Waterman is not operated as a plug-in with shore power recharging, but it could be, according to Joe Hudspeth, BAE’s business development manager, global marine. “The beauty of our system is someone can install a HybriGen system today with the variable-speed genset technology, and as their shoreside infrastructure

Ørsted A/S Bruce Buls photos

Capt. Kelly Greenwood (left), likes using the hybridelectric propulsion system on the Waterman, but said it ‘defi nitely took a little while to get used to it, especially when the engines kick off when you’re underway.’

improves, they can simply rely just on shoreside charging,” Hudspeth said. “They can add more batteries, if necessary. They can take out the generators or they can leave them in as emergency backup. We don’t have to change any of our hardware, any of our hybrids today can be fully electric tomorrow just by adding more batteries. Nothing else needs to change.”

Going all-electric is the plan for the Waterman II, now getting design and engineering completed by Seattle’s Glosten. Whether the vessel will have emergency gensets depends mostly on the Coast Guard, said Scott. “They might be OK with completely redundant systems, like the Maid of the Mist”, an all-electric passenger boat that operates in Niagara Falls, N.Y.

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Washington State Ferries, BC Ferries and many other ferry services worldwide is zero emissions, especially greenhouse gases. And if getting there saves money on fuel and maintenance, so much the better. The most viable method for getting to zero right now is batteries, ideally charged from a clean grid of shoreside power.

Damen’s Grunstra said the battery market is improving all the time. “I think there are maybe 100 kinds around the world at the moment,” he said, “so you can choose whatever battery you like. If you wanted to charge the batteries very quickly, you might want a certain chemistry. If you want to take a lot of power in a short amount of time, you will need to choose the chemistry that is suitable.”

And Hudspeth said electric systems are increasingly able “to get more energy out of smaller and lighter-weight energy storage systems.”

Capital cost for hybrid-electric is “de nitely more,” said Scott, “but return-on-investment should repay that in not that many years, especially with the price of fuel being what it is.

Grunstra agreed. “The interesting thing about batteries and electric power is that in the long run it’s cheaper,” he said. “If you only have a future of ve years or 10 years, it may not be the case that electri cation makes sense, but if you have a window of 40 years like BC Ferries, it’s a no-brainer. You are de nitely cheaper with electric over diesel.”

Electric power is also being adapted for near-future, high-speed ferries. Hudspeth said BAE will be powering the world’s rst all-electric, high-speed passenger ferry, the Beluga24, for Green City Ferries in Sweden. The carbon- ber, foil-assisted, 147-passenger catamaran will have HamiltonJet waterjets at the end of the BAE powertrain. Battery-electric will be used for short runs and hydrogen fuel cells will provide electricity for longer journeys.

Back in Puget Sound, Washington Maritime Blue, a nonpro t consortium of marine businesses and organizations, is spearheading a project to design and build a high-speed hydrofoil for passenger service between Bremerton and Seattle. The boat will be built from carbon- ber materials and powered by battery-electric propulsion. Glosten is working on the design/engineering and Bieker Boats in Anacortes is working on plans for the carbon- ber structure. Funding has been found for this part of the project. Construction grants are still being sought.

WSF says it has enough money on hand ($1.33 billion) to convert its three largest boats, the Jumbo Mark IIs, to build ve hybrid-electric Olympic-class ferries, and to establish recharging power in central Puget Sound. Construction of new ferries is legally restricted to Washington state shipyards. Vigor is the largest and has built all of the Olympic-class ferries to date, with Nichols Brothers Boat Builders building some of the boats’ superstructures. Kitsap Transit also has secured funding for Waterman II.

With the advent of electric cars, busses and trucks as well as electric boats, the grid’s capacity will be stretched as never before in the years to come.

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