Manly ferry propeller fail: More problems for new Emerald class vessels

Commuters could be shafted in the lead-up to Christmas with another new Manly ferry having mechanical issues — this time with its propellers

Propeller shafts on one of the new Manly ferries have had to be replaced after another fault was identified in the plagued foreign-built fleet.

A tug boat was needed to tow one of the new Emerald Class vessels in for repairs on Monday evening, with the boat taken out of the water for modifications.

The Clontarf was on Sydney Harbour on Monday evening when its captain called for help.

A ferries insider said the vessel was towed to a floating dry dock at inner-city White Bay where the propeller shafts will be removed.

Shafted: The new generation 2 Emerald-class ferry, Clontarf, seen here with the Fairlight and the Balmoral, is set to have its propeller shafts removed because they are too noisy. Picture: NSW Government

It is understood the noise coming from the ferry’s drive train was unacceptable and there were also concerns the Clontarf was difficult to control.

The noise was said to be caused by excess vibration.

The insider said Transdev would not be accepting the boat from the shipbuilder, Birdon, based at Port Macquarie, until the problem was rectified.

A Transdev spokeswoman said the Clontarf was put into dry dock for “modification works … including minor improvements to the propellers”.

The ferries were built in China and Indonesia.

Transdev, a private company, operates Sydney Ferries on behalf of the NSW Government.

This latest ferry snag comes after the discovery of welding defects in the hull of another of the Generation 2 Emerald Class ferries, the Balmoral.

While the welding issues on the Balmoral have been described as “minor”, the ferry insider claims at least 26 cracks were found in the hull’s framework after the vessel was out in large seas in late November.

The new Generation 2 Emerald Class ferry, Balmoral. Numerous cracks were found in the welds within the hull. Picture: Transport for NSW

Transdev was running trials of the Balmoral in large swell after another of its new Manly ferries, the Fairlight, had been withdrawn from service due to big seas.

During the large swell trial, a window on the Balmoral’s upper passenger deck shattered and one of the bolts holding the starboard rudder in place became extremely loose and there were concerns the rudder was close to falling off.

An independent marine surveyor was called in after a crew member discovered cracks in “26” welding joints on the Balmoral. Picture: Nathan Edwards

It has also been revealed that Sydney Ferries will have to install a new gangway at Manly Wharf 1 because passengers can’t be loaded or unloaded if there is an extremely low tide. The gangway becomes too steep.

The insider told the Manly Daily that after the Balmoral had been through the large swell trial, a crew member discovered several cracks in the ferry’s ribs or stringers, which are part of the internal hull framing.

“As a result, Transdev engaged an independent Marine Surveyor to inspect the Balmoral. His report noted 26 cracks in the welding joints within the vessel’s hull.

“I am told these cracks are in the hull framing and are a separate problem to the broken window.”

The new Manly Ferry "Fairlight" leaving Circular Quay on a cold and windy day. Picture: Adam Yip

The Transdev spokeswoman said “a number” of welding defects had been found.

“A potential defect was identified in the weld of a secondary support structure inside a hull void of the Emerald Class vessel Balmoral during a routine inspection,” the spokeswoman said.

“[A] surveyor report confirmed a number of welding defects that are minor, isolated, and do not compromise the overall structural integrity of the vessel. Such welding defects are very common in aluminium boats and do not impact the Balmoral’s operation.

“The vessel was trialled (Monday) morning and returned to service the same day. All the defects will be addressed as part of upcoming maintenance.”

Two of the vessels, which can carry 400 passengers, are already on the Manly to Circular Quay route. But critics have said the new ferries would not cope with large swells across Sydney Heads. The Government and Transdev have repeatedly said they were purpose-built to operate in heavy swells up to 4.5m.