Engine Room to Warehouse: Crew That Keeps the Ferries Running

NORTH CAPE MAY— It’s no small feat to keep a fleet of ferryboats in operation seven days a week, every day of the year.
While ferry passengers may think it takes a handful of personnel to operate a ferry, there are a number of people working behind the scenes.
All the marine trades are represented at the ferry shop including welding, electricity and electronics.
Three mechanics maintain ferry engines including overhauls, according to Bill Greenling, senior manager of marine maintenance. The ferry has two U.S. Coast Guard certified welders, he said.
The ferry has an in-house machine shop. Greenling said problems are often repaired while the ferry is loading and unloading cars and service resumes without interruption.
The Coast Guard inspects each boat four times per year, said Greenling, which adds up to 20 inspections per year with five boats. The American Bureau of Shipping does an annual inspection of each ferry as well.
The ferries have flat bottoms and only draft between seven and eight feet of water, said Greenling. They have twin propellers.
Few members of the public have seen the engine room of one of the Cape May-Lewes ferries. The Herald went below on the M.V. Twin Capes were two Fairbanks Morse 12-cylinder diesel engines are housed.
Each engine produces 2,060 horsepower each. The engines do not reverse so the captain reverses the gear box to back up the vessel, said Greenling.
Mechanic Rich Gregory said the engines have opposing pistons with two crankshafts.
The engines date back to the 1970s and are no longer manufactured. Gregory said the design of the engines dated back to World War II and originated in submarines. They were also used in locomotives.
“They are basically bulletproof, they’ll last forever,” said Gregory.
Gregory said the engine rooms on all five ferries are essentially identical. A two-person crew is always in the booth of the engine room during sailings.
DRBA conducted a study on the topic of purchasing new ferries and the cost to maintain the existing fleet over the number of years while hulls of the vessels are serviceable, according to Port Captain Bryan Helm. The next generation of ferries here may have catamaran hulls, he said.
The current Cape May-Lewes Ferry fleet numbers five boats.
“Our ridership has declined so much over the past five to six years, the need for the fifth vessel may not be there anymore,” said Helm.
He said the fleet could be reduced to three or four boats in the future. Fewer vessels mean less maintenance and insurance costs, said Helm.
“You still want to provide the same service to the public, so it’s a little bit of a balancing act but a new vessel would be a little bit faster…” he said.
At this time, Cape May-Lewes Ferry is looking at refurbishing the interiors of the boats with new seating and new carpeting.
“We’re always looking to add amenities for the customer, make the ride more enjoyable and more convenient,” said Marketing Manager Michael Porch.
Wi-Fi, flat screen TVs and teak deck chairs have been added to some of the boats.
The current ferry fleet is the second generation of vessels. The first fleet came from the Little Creek-Cape Charles Ferry operating across the Chesapeake Bay until 1964. That ferry ceased operation in 1964, replaced by the Chesapeake Bay Bridge-Tunnel.
The Cape May-Lewes Ferry purchased the steam-powered boats, one of which was a former World War II landing vessel.
In 1972, the DRBA signed an $11.7 million contract with Todd Shipyards Corp. to construct three new ferry vessels. The Authority began plans for its fourth new vessel and in June 1981, the MV New Del, later renamed the MV Cape Henlopen, was put into service. Four years later the fifth new vessel was put into service and named the MV Cape May.
The ferry maintains an extensive warehouse storing everything from lines to tie up the boats, to life raft canisters, cleaning supplies, engine and generator parts, spare pumps, hoses, filters, uniforms and brochures.
Warehouse Supervisor John Berg said the marine industry is unique in that “things just don’t come off the shelf.” He said some parts may take six to 18 months to receive because they are cast in metal.
“Although we may not use this part often, if it’s not on the shelf and the boat breaks down, it won’t be able to go,” said Berg.
His inventory included huge clutch rings, reduction gears and bearings. Berg said the ferry mechanics have enough talent, if handed a piece of steel, they can often fabricate parts needed for the boats.