Client: Washington State Ferries (WSF)

Challenge: Washington State Ferries aimed to modernize its aging fleet, reduce carbon emissions, and improve operational efficiency. The goal was to convert one of its largest vessels, the 202-vehicle M/V Wenatchee, from a diesel-powered system to a hybrid-electric propulsion system. This project was a critical first step in WSF’s long-term System Electrification Program, which seeks to modernize six existing ferries and build 16 new hybrid-electric vessels by 2040. The conversion project was complex and required extensive retrofitting of the vessel’s core systems while ensuring its continued reliability and safety for public transport.

Solution: Vigor Marine Seattle was contracted to undertake the complex conversion of the M/V Wenatchee. Over a period of nearly 21 months, Vigor’s skilled workforce, comprised of approximately 700 employees and nearly 600 union-represented craft workers, executed the following key tasks:

• Removal of legacy systems: The team successfully removed two existing diesel generators to make room for new equipment.
• Battery room construction: Two new battery rooms were constructed and fitted with 864 battery modules to power the new system.
• Propulsion and control system installation: Vigor installed new propulsion control systems, thousands of feet of new electric and fiber optic cable, and upgraded various onboard systems.
• Passenger area upgrades: While the core work was on the propulsion systems, the project also included upgrades to passenger areas to enhance the user experience.

Result: Vigor Marine successfully completed the conversion of the M/V Wenatchee, making it the largest U.S. passenger ferry to be electrified. The vessel was delivered back to Washington State Ferries and is currently in service after completing sea trials and crew training.

When shore charging infrastructure is completed and in place, the M/V Wenatchee – along with its sister ships, the M/V Tacoma and M/V Puyallup, when they are successfully converted – is projected to:

• Reduce diesel consumption by over 4.7 million gallons annually.
• Cut greenhouse gas emissions from these three vessels by approximately 95%.

The successful completion of this project highlights Vigor's expertise in large-scale vessel modernization and its role in helping Washington State Ferries achieve its sustainability goals. This project is a significant milestone for both Vigor Marine and Washington State Ferries, paving the way for a more sustainable future for the region’s marine transportation and a more reliable ferry system that supports one of the nation’s largest economic regions.