MADONNA IS HOME! - 38.0

Madonna shortly after departing Bay Shipbuilding Friday
afternoon, enroute to Detroit Harbor on delivery run.
(Fincantieri Bay Shipbuilding photo)

Detroit Harbor, Washington Island -

When a vessel is designed, constructed, launched, sea trialed, and then sailed home, the hope is always that it will be right: feel right, look right, handle right.  Each step along the way, including the components chosen, contribute to the overall product:  engines, gears, shafts, propellers, electronics, seating, flooring, deck coatings.  If one or two elements miss the mark the whole can seem off and create disappointment.  And until the whole is assembled, sea-trialed and sailed, judgement cannot be properly given.

Madonna shadowed by Washington Island Coast Guard's
SAR vessel as she entered port.  (Tyler McGrane)

That is a part of the mystery of shipbuilding: built upon science, improved from existing examples, and put together by those who know their trade well.  Still, always a bit of a gamble as the whole comes together.

A portion of the small fleet that trailed in the Madonna's
wake.  (Tyler McGrane)

In the case of Madonna, the new ferry designed by Seacraft Design and built by Fincantieri Bay Shipbuilding, both Sturgeon Bay entities, the process and the product thus far speak of great success.

Added to the characteristics listed above is functionality, its acceptance and trust by those who sail her, by those who stand upon her decks as passengers and enjoy her services.

We know some unknowns await to be answered, but many major hurdles have been crossed.  Gauging by initial crowd reactions, for there were several hundred who came out last evening by boat and by car to see the new ferry, it meets the criteria of a winning vessel so far.

Madonna and Coast Guard escort.
(Kim Toro)

Last-minute items had been sorted out during this past week, a press to resolve "head scratchers" such as improvement of the steering system (check!) and the suction for pumps that energize the fire mains and sprinkler systems (check! yet again).   Yard personnel, vessel designer, and WIFL personnel put their heads together to best resolve those issues.

A Certificate of Inspection was granted by the U. S. Coast Guard, required before carrying vehicles and passengers.  A check was exchanged, a signature of ownership given to mark the transfer. and hands were shaken by Todd Thayse, Fincantieri General Manager and Vice President, and Rich Ellefson, WIFL Construction Representative and Company Vice President.  That was late on Friday morning.

A mild breeze blew from the south as Rich
Ellefson made his approach, then swung the
Madonna's stern 180 degrees to nail this first
landing at the Island dock.  (Jim Rose photo)

By 2:00 pm a number of vehicles were run aboard the car deck, mooring lines were cast off, and Madonna headed north for home port.

On board were Hoyt and Rich and their two young sons, Magnus and Brody, observer Terri Moore (who in a "normal summer" would drive the Cherry Train), and a number of key Bay Shipbuilding personnel.

Among the latter was Steve Propsom who was on a "final lap" over the waters of Green Bay aboard his last project assignment as shipbuilder and project manager.  Upon mooring at the Island, lines were made fast to the Island pier and Steve's 46-year career in local shipbuilding came to a close.  Retirement adventures would next deserve his full attention.

Along with approximately 15 other small craft, we on the Moby Dick fell in behind the Washington Island Coast Guard in helping to escort Madonna in her last mile to port.  We were thrilled by the sight, and we absorbed each authoritative air horn blast as Rich Ellefson issued the "long salute".  Such moments in one's life (and career) are rare, especially when they happen on such a beautiful Friday evening, joined by several hundred onlookers. We sensed community pride in product, and not just our own.  We are convinced this vessel will continue to meet expectations.  

Madonna, positioned for backing in to south ramp.
Rich stands at the stern controls, but there's also
great PH visibility, should the operator chooses to remain
in the wheel house throughout the landing evolution.
(Jim Rose)

No sooner had Rich swung the Madonna's stern to the pier, pressing the rub rail against the dock tires, and the ramp was lowered and vehicles on board were driven off.  Dozens of folks on the pier, most wearing face masks and mindful of the Covid-19 threat, had by that time lined up to come aboard for closer inspection.  This parade of viewing lasted for the better part of an hour, before the crowd thinned.  The crew then removed pallets of paint, lube oil and spare parts from the deck, stores intended for future maintenance and repair projects, before laying the new ferry port side to the pier for the evening.

First line over, secured by Hoyt Purinton, approximately 6:30 pm.
(Jim Rose)

This morning, as a line of thunderstorms approached, Mary Jo and I got up early, still dreaming about the evening before.  We drove out to the ferry dock to see if the Madonna, a longtime dream, was still moored securely at the Island pier.  She was.

We returned home satisfied, but excited for her future appearance on local waters.  We look forward, as do crew members of the Ferry Line and our many customers, to its first regular service.

Steve Propsom (Bay Shipbuilding), Magnus and Hoyt Purinton,
and Rich Ellefson, upon arrival, relieved and satisfied at successful
delivery, and to be joined by well-wishers.
(Kim Toro photo)

Madonna is about to enter dedicated ferry service, for what we anticipate will be decades of faithful operations--winter and summer--for Washington Island, its residents and visitors.

All off this has happened during the 80th anniversary of Washington Island Ferry Line, Inc., an additional reason to celebrate.

      -  Dick Purinton

PS -  I was busy steering the Moby Dick last evening and wasn't able to take photos.  Thanks to all who sent me a selection from which to choose.

Steve Propsom with author.  Steve retires after
46 years in area shipbuilding.  One note: this writer also
celebrates 46 years with the Ferry Line, in late October.
Jim Rose, WIFL employee (and the photographer here)
reminded us that his first day as a Ferry Line ticket seller
was the day of the Robert Noble christening, June of 1979.
Steve began his career as a part of the Peterson Builder's work
force on that ferry project.
We've each had the pleasure of observing the bay freezing
over--and then thawing once again--many times.    

MADONNA CONSTRUCTI0N - 37.0

Capt. Joel Gunnlaugsson with Fincantieri
Senior Project Supervisor Steve Propsom, upon
return to port after sea trials.  Broom signifies
a "clean sweep", the satisfaction of
requirements for U. S. Coast Guard Certificate
of Inspection.  (Purinton photos in all cases)

Detroit Harbor, Washington Island -

Having been absent here for a few weeks in reporting on construction, during which time the christening took place at Fincantieri Bay Shipbuilding, we're now back to continue the story, with particulars of where the new ferry Madonna stands in terms of finishing and delivery.

First, we need to update statements regarding the steering system, because the first assessment for remedy didn't prove out.

One of many details added in the past weeks:
a step for crew to reach and tie mooring lines.

During Builder's Trials, a test run of the vessel's systems, its engines, electronics, etc., it was discovered that steering responsiveness seemed to lessen over time.  Greater revolution of the pilot house helm was required to move the rudder just a few degrees. The cause was determined to be hydraulic oil heating and thinning with longer running time time.  The probable fix appeared to be reduction of heating by means of installing a lower volume output hydraulic pump, and by enlarging the diameter of the piping from pump/reservoir to pilot house and to the steering rams back aft, a rather long run with many angles and turns in the piping.

Fincantieri pipe fitters began work right away and installed larger inside diameter piping.  But as for a lower output, CAT engine-compatible hydraulic pump, none was found in the marketplace.  Instead, a flow valve was installed, along with an oil cooler (fed by the same pump that flushes stern tubes). During a second Builder's Trial, performed two days ago on Monday, July 13, the steering seemed to perform well.

As can often happen with more time spent underway, a few more items also came to light, and they were highlighted on the punch list.

After Monday's successful underway trial, a second sea trial was then scheduled for Tuesday, July 14, this time with a U. S. Coast Guard Marine Safety Detachment observer on board.   This sea trial fell almost exactly 1-1/2 months beyond the original estimated Madonna delivery date, a point of secondary importance to getting steering, as well as other vessel functions, to where they needed to be.

In this photo, you're looking up the ladder
that leads from engine room to main deck.

Madonna engine room has come a long way:
a complex space of piping, wiring and machinery,
but with room to move about.  A Bay Ship
mechanic can just be seen between generators,
monitoring fluids and temperatures.

Clean bilge; CAT engine control boxes;
bilge piping manifold beneath.  One example of
well-laid out, yet separate, systems.

We departed the Bay Shipbuilding slip at 10:00 a.m. and proceeded to the outer bay, with approximately a dozen yard personnel plus five Ferry Line representatives on board.

Enroute to sea trials, Madonna passed
Cason J. Calloway, inbound to Bay
Shipbuilding for repairs.

At the conclusion of several drills and with Joel Gunnlaugsson
at the wheel in the pilot house:
Rich Ellefson, Steve Propsom, Jeff Cornell, Dan Petersilka and
Hoyt Purinton.

By the time we reached Sherwood Point light, having passed port-to-port in the entrance channel the Cason J. Calloway, inbound to the shipyard for repairs, the Madonna's engines and fluids were warmed to anticipated operational temperatures.  Steering maneuvers, the shifting of generator loads, "crash stops" (full back while carrying typical forward momentum), a man overboard drill, and demonstration of good water pressure on main deck fire hydrants, were among items checked off during the several hours underway.  The sea trial was termed a success, and the number of items on the "to-do list" were trimmed even further.

A man overboard drill was conducted using a dummy
designed for such an evolution (approx. 150# with water
weight).  Shown:  Coast Guard observer Tom Hunninger,
Jeff Cornell, and Hoyt Purinton on bow ramp.

Another day or so will be used to tie up remaining loose ends, and to reconcile our standing with the Fincantieri yard regarding "who pays for what."  Those discussions may continue for some time, but a general understanding must be met in order to transfer ownership, and satisfy builder and owner product expectations, contractual items met, and with an appropriate USCG Certificate of Inspection forthcoming (like having a motor vehicle license plate, only with particulars of operation spelled out in detail).

A view of mezzanine cabin passenger seating.

When can we expect Madonna to be underway for Detroit Harbor?  Perhaps Friday.  We'll have to see.

  -  Dick Purinton

Upper deck passenger seating and pilot house.

MADONNA - UNDERWAY - 36.0

Madonna underway off the stone quarry, outer bay,
during builder's trial, Friday afternoon, June 19.
(Photo by Erich Pfeifer)

Detroit Harbor, Washington Island -

After long days of chasing down and correcting details, some small, some large, Rich Ellefson reported that Madonna would sail from the dock for the first time.  This would be the "builder's trial" in which various components and equipment would be tried and tested, including running main engines up to temperature while various systems were monitored.   Apparently things went well (or, I just didn't hear about the glitches!).

Bay Ship and Ferry Line representatives gathered for
briefing on main deck prior to leaving pier, and again
upon their return dockside.  (Hoyt Purinton)

Hoyt Purinton, Erik Foss, Joel Gunnlaugsson and Jeff Cornell joined Rich for the day, their first opportunity to see and experience the vessel underway.  A few photos are shown here of the Bay Shipbuilding and WIFL crew members in conference, and on the bridge.   With a few more days' work, the vessel could be ready for U. S. Coast Guard sea trials by mid-week.

Ferry line captains Jeff Cornell, Erik Foss, Rich Ellefson
and Joel Gunnlaugsson on upper deck.

Christening plans

In a departure from christening of the last several ferries, a ceremony will take place within the shipyard, with members of the Fincantieri Bay Shipbuilding workforce present, along with a few invited guests.

We'll hold details of the christening back a few more days as we reflect back on other ferries and the christening ceremonies that took place, both at the shipyard and here on Washington Island, when the public was invited to take part in the festivities.

A few panels and wires yet to be made permanent,
but the pilot house was functional for builder's trial.
(Hoyt Purinton)

Several reasons led to our decision to hold the christening at the shipyard.  One, Fincantieri Bay Shipbuilding wishes to recognize its workforce for a job well-done on a product that will sail in their "backyard," so to speak.  We will join the yard management in offering our thanks, and congratulations for a job well done.  A substantial amount of pride has been evident in workers who participated in this vessel construction, intended for Door County service, what could easily be 4-5 decades or more of continuous use for ferry transportation.  This occasion also highlights the importance of shipbuilding to the area's economy, and the contribution building such a vessel adds to Door County and the region.  Another reason for holding the christening within the shipyard confines is that with Covid-19 as a threat to public health it becomes easier to hold the christening in a controlled setting.  All participants will be asked to wear a mask (the Bay Ship workforce has been doing this for five weeks or more).

In wheelhouse:  WIFL construction supervisor and vice-president Rich Ellefson
with Steve Propsom, Fincantieri Bay Shipbuilding Senior Project Supervisor.
(Hoyt Purinton photo)

We'll provide more detail in a few days' time.  -  Dick Purinton

MADONNA PROJECT WINDS DOWN - 35.0

Detroit Harbor, Washington Island -

This year has so far been one that requires patience and waiting:  waiting for the pandemic to cool down, for the economy to open up, and for a return to broadened horizons.   And for a moderation in water levels.

So far, success on these fronts is only partial.  Sidelined Great Lakes freighters Wilfred Sykes and H. Lee White, their crews gone home on an unexpected mid-season break, framed the nearly finished ferry Madonna at the Fincantieri Bay Shipbuilding yard in Sturgeon Bay.  The Covid-19 pandemic and greatly slowed economy has led to a sufficient supply of ore pellets and other materials, and that, in turn, caused layup of several freighters.

I spent several hours Tuesday morning inspecting the Madonna's progress, along with Hoyt.  Numerous details that would otherwise not have been noticed were pointed out by Rich Ellefson.  Rich has followed the project as close as anyone since first frames and shell plating were assembled indoors last fall.

At present, most work is either in the engine room, pilot house, or
main deck, as seen here.  Much of the electrical wiring has been
run but needs tucking in, bundling and connecting to lights
and outlets along the bulwarks and over head (which will
have slightly more than 15-ft. clearance for trucks and
special equipment.) 

This project, now a few weeks beyond original planned delivery, is down to details - important details to be sure - with hopes that main engine start-ups will happen yet this week.  If wiring and several other tasks fall in line, according to Fincantieri Project Supervisor Steve Propsom, an underway sea trial may yet happen toward the end of next week.  But, those numerous important details must first be checked off the work list.

Pilot house wiring requires the most time remaining to
completion, it seems, and with only so much room,
electricians are in close quarters as they 
complete their work.

Slowly making my rounds on board, and careful not to get in the way of workers, wet paint or equipment, I observed the final flushing of hydraulic piping for the ramps/fire pump loops.   One painter touched up along the starboard bulwarks and waterways.  Another painter made final touch-ups to the aft stairway.  Treads were being installed on the upper deck stairway.  Two workers, one with garden hose, applied water pressure to cabin windows and checking for leaks around the window casing perimeters.   Inside the pilot house, two Faith Electric electricians sorted out the gobbledegook of wiring for gauges and switches.  Most pilot house windows remained covered, protecting them from paint, welding sparks, and so forth.  Much work has yet to be done in that space, but only so many workers can productively fit into the confines.

Just the same, I could gauge the relationship between adjoining upper deck spaces and the number of steps leading to the wheel house, a distance operator and crew will have to cover on a regular basis. The commanding view of bow and stern from that vantage was evident.

On the stern deck, hydraulic lines are being flushed
by circulating oil under pressure through a fine micron
filter until little or no grit remains.  The reel of ramp 
wire is in foreground.
Later that day, engine soft patches were to be tested
for water tightness, as would deck access cover
gasketing for the below decks spaces.

The bow ramps and operating hydraulics seemed nearly set.  A reel of ramp cable was nearby, on deck, wire ready to be inserted through the sheave system, one end fastened to a below-decks winch and the other to be dead-ended on a nearby king post.

Rich pointed out the man overboard winch and the anchoring equipment in the starboard bow.  The anchor selected is a very light (67 pounds) Danforth-style anchor.   Anchors on our other ferries weigh in at around 200#, and most are connected to several hundred feet of heavy chain.  Madonna's anchor (like the ferry Washington) will be tethered to the ship by a stout nylon anchor line.

Rich also pointed out numerous features along the starboard rail, where a sewage pumpout station, lube oil fill, and a diesel fueling station were tucked in as closely as possible to the bulwarks, out of the way from vehicles and passenger feet.  Such details seem matter-of-fact, but each one requires special consideration in their placement, from designers, welders, pipe fitters and electricians, oil order to keep the rail as "clean" as possible, yet allowing functional, operating equipment.

In the engine room, FABICK CAT representative Don Toyne and service technicians wired up the main CAT engines, a process estimated to take 2-3 days prior to initial startup.   Don has been front and center on numerous ferry projects for WIFL, including repowering the Robert Noble and Washington,  and also during regular tweaking and software updates for Arni J. Richter engines.  Once again, even though this engine room has a fairly generous amount of room, with four or five technicians it's best to give them room to work.
I went above.

Steve Propsom, Hoyt Purinton and Rich Ellefson
discuss details yet to be completed.

I went above, and there I met with Steve Propsom and his daughter, Stephanie, an attorney for Fincantieri Bay Shipbuilding.  Steve has been with this project as Bay Shipbuilding's senior supervisor.  He postponed his retirement date when June 1 passed and with it thje estimated delivery date.  There is a reasonable certainty the delivery will be prior to July 1st, but regardless, Steve is prepared to stay on longer, if necessary, to see the project through, completing 46 years in his Sturgeon Bay shipbuilding career.

Is it safe to begin thinking more seriously about a christening date, I wondered?  Not quite.  But closer, ever closer!  -  Dick Purinton

MADONNA "LAUNCH" - 28.0

Steve Propsom photo of dry dock submergence.

Detroit Harbor, Washington Island -

What can be termed the "launch" of the new ferry Madonna took place in the floating dry dock at the Fincantieri Bay Shipbuilding facility, just before 10:00 a.m. today.   Photos sent by Steve Propsom showed water beginning to flood the dock, then rising up the sides of the hull prior to floating.

First wetting of the hull.  (Steve Propsom)

Selvick Towing tug awaits the hull to float free from blocks before towing the vessel pier side in slip #9, just south of the main Ship Building office building.  Work will continue as soon as the vessel is moored and a gangway for workers set in place.    -  Dick Purinton

Preparations were made late Thursday to clear the dry dock floor
of equipment, making the vessel ready for entering the water early
Friday.   Last-minute paint touch-ups were still ongoing, at left.
(Rich Ellefson photo)

MADONNA - FINAL PUSH - 27.0

Detroit Harbor, Washington Island -  

Rich Ellefson sent me another report last evening, along with photos he'd taken late in the day.

While this posting is being put together (7:30 a.m.) it is likely the flooding, or sinking, of the floating dry dock is underway.  Flooding of the dock floor will be done in measured steps to ensure no leaks are within the vessel, i.e., valves left open, connections not tight, and so forth.  When the water level on the hull reaches approximately a three-foot depth, each below decks space will be entered and carefully examined to determine if bilges remain dry.

The Coast Guard approved the rudder and propeller installations, and so the vessel can be floated. Normally a major step in vessel construction, often combined with a christening ceremony, breaking of a bottle on the bow and so on, today's "launch" becomes anticlimactic in comparison to the amazing progress shown toward finishing this vessel, preparing it for underway sea trials.  Much work is yet to be done, and the quickened pace continues.

Here is Rich's report (and I've just received his note that the walk-thru of spaces is now complete):

Well it looks like we hit the necessary milestones for our launch tomorrow. Both ramps are on and chained in the vertical position. The strong backs you see on the back side of the ramps are being removed tonight and the welds will get ground flat. The stripes on each side are done and the second shift painters are touching up the black on the sides as well as around the stern where the anodes were attached. 

USCG was out here today three different times for final inspections on rudders, engine room entryway weld inspection and then to oversee the tonnage measurements. The final measurements came in very close to spec., we were a quarter inch short on overall length and a quarter inch long on overall height which is measured keel to car deck at midship. The beam measurement came in exactly 40 ft. as per the spec. These measurements needed to be verified for getting our Tonnage Certificate. The prop nut straps are welded to the end of the shaft, similar to our other vessels. 



Billy Lemieux wanted to also bolt the sides of the strap to prop nuts, preventing any chance of the straps being able to spread. Lots of activity in the engine room, steering void and the forepeak with all the piping and electrical work going on. 

The pilothouse is set in location and just needs to slide 1 inch aft, which will take place in the days to come. The insulators are insulating the engine room entryway tonight, so the electrician's can start pulling wires up to the upper levels. The engine room still has a long way to go with all the piping that remains as well as hydraulic tank foundations. 



Our schedule for tomorrow is to be onboard at 0700 for a final walkthrough of all voids and engine room, followed by a walkthrough of drydock to make sure everything is secured and all painting below water level that was disturbed is touched up. They will start flooding at 0800 and stop flooding when we have three feet of water on the hull. At that point there will be another walkthrough to make sure everything still looks good internally. After that walkthrough they will continue to flood until we float free. Selvick is scheduled to arrive at 0900 for towing us to berth 9 where we will remain until sea trials in late May. 



Steve has asked Mark (Mark Pudlo, naval architect) to be here at 10:00 or at least available once we are dockside for the initial freeboard readings. That is the plan they have as of now and hopefully everything goes well...  (above text and all photos by Rich Ellefson)

The engine rooms and wiring remain as a major task.  With insulation installed in companion ways, wiring runs can be completed.  Faith Electric of Green Bay is the subcontractor hired by Bay Shipbuilding.  - Dick Purinton

MADONNA - 24.5

Detroit Harbor, Washington Island -

Todd Thayse, President, and Steve Propsom, Senior Project Manager, were on hand early Friday morning at the Bay Shipbuilding facility to observe the Madonna as it was transported from the Fincantieri Bay Shipbuilding paint shop to the nearby floating dry dock.

Madonna arrives at floating dry dock.  Vessel
will be turned then rolled on to the dock floor.

Whether these photos should be credited to Todd, or to Steve, I'm not certain, but they were forwarded to me by Rich Ellefson who was at work here on the Island at the time.  The move was on schedule, undertaken early in the day so that other work to complete the vessel could begin at once.

Specialized Fagioli transport units make such 
a move relatively easy.  Work accomplished, they
will be shipped back to Fincantieri's Marinette yard.

With exception of the pilot house, shafts, propellers 
and rudders, which will be
installed soon, all major components are onboard.

Fagioli units removed, Madonna is now on blocks within the floating dry dock
at south end of the Fincantieri Bay Shipbuilding yard.  Five more weeks, maybe six,
and the new Washington Island ferry should be ready for delivery.

Since there is little I'm able to add to this step of the project, I'll let the Fincantieri photos speak for themselves.    -  Dick Purinton

Added note:  This Monday morning I received several more photos from Steve Propsom that I will include below.  -  DP

MADONNA PROJECT - 22.0

Steve Propsom emailed this photo minutes after I finished 
the blog below, and he said that all black had been given
one coat. Workers were starting a second.

Detroit Harbor -

A little raking, a walk in the nearby woods, wood carving, then time at the computer.  Pretty soon the sun begins to set and another day is nearly done.  One similar day after another.   But, we're doing well, practicing what is important for us and the larger whole, at least that's what we tell ourselves.  When I spoke this morning with friend Jim Legault, at his home near Merida, Mexico where he's been for the last three months, his situation is quite similar.  Most businesses are shut down there, too.



Fincantieri's work schedule calls for painting the ferry this week. That, and the idea of less exposure to others, induced Rich to remain on the Island this week.  The photos here, and today's short report, come from Bay Ship Senior Project Manager Steve Propsom.  Painters are at it inside the paint shop, and I will let Steve's email tell the story:

Plans always change, so much for the half day today, working all day. I will try to snap a few shots this morning of the paint in process which is making good headway. White is nearly all on and working the black on the hull today. Plan to non-skid the decks next week. Our plan is to set up for the rollout mid next week and to roll onto the floating dry dock next Friday the 17th. We want to take advantage of being inside the paint building where we have ideal paint conditions. 

Yes we are in full force here in the yard and on the project. 



As I stated in my last posting the project may be running just a few days behind planned launch target date, but that is not of major consequence to the Ferry Line at this juncture.



For the shipyard, though, it is important to set this vessel in the floating dry dock, ready for wetting the hull.  With that move accomplished, the specialized transporter needed to roll the vessel through the yard and to the dry dock can be shipped back to Marinette.





Here on the Island traffic continues with the four trips per day, light loads but that's OK for now.

Happy Easter, everyone.  -  Dick Purinton