EXCLUSIVE: Deep inside Bluebridge's new engineering powerhouse

Below deck

We’ve all crossed Cook Strait. But few have stood inside the beating heart of a 26,000 GT Italian-built ferry, with hatches open, lines exposed, and nothing off limits.

Three levels of raw mechanics and engine rooms in Livia, the Bluebridge Ferry which operates between Wellington and Picton in New Zealand // Photo credit: Kirsten Thomas / Boating New Zealand

Thanks to First Officer Joe, Boating New Zealand went below decks for a full walk-through of Bluebridge’s newest vessel—Livia—from control room to crankshaft. It’s one of the most technically advanced ferries ever to operate in New Zealand.

“She’s a solid ship,” says Joe. “Built for Italian service, ice-class, heavy steel, designed to run hard and run long.”

Simple, strong propulsion systems

Unlike diesel-electric systems used on some other ferries, Livia runs two direct-drive MAN diesel main engines, connected via gearboxes to controllable pitch propellers, allowing thrust to be varied without changing engine speed.

“You pivot the blades for thrust, just like a turboprop,” Joe explains. “More pitch, more drive. Reverse the pitch, and you go astern.”

- Advertisement, article continues below -

The shaft turns at about 160 RPM, reduced from the engine’s 500 RPM via gear reduction. At full chat, she can exceed 23 knots, though normal crossings are done at a fuel-friendly 17–18 knots.

The Livia runs two direct-drive MAN diesel main engines. These are massive machines. // Photo credit: Kirsten Thomas / Boating New Zealand

Redundancy and electrical generation

Livia runs three Caterpillar 16-cylinder diesel gensets, supplemented by shaft alternators that draw power from the main engines underway.

When in port, she operates on just one generator to cover “hotel load”, about 0.4 megawatts, keeping emissions and fuel costs low.

If needed, the ship can isolate power control from the bridge and revert to manual crisis management via the control room. “One switch,” says Joe. “And you’ve got full backup.”

The massive Diesel Generators, there are three in total. Bluebridge Ferry, Livia. // Photo credit: Kirsten Thomas / Boating New Zealand

Smart ballast and automation

Livia uses a Kongsberg Vessel Automation System, controlling ballast, bilge, tank management, power, and ventilation across the ship. Changes can be made from the engine control room, the bridge, or the vehicle deck control centre.

- Advertisement, article continues below -

Below deck on Bluebridge’s Livia, the Power Control Wall is a sight to see! // Photo credit: Kirsten Thomas / Boating New Zealand

Ballast is managed automatically, constantly shifting water between heeling tanks to maintain acceptable angles of list when loading freight.

And here’s a world-class addition: Livia uses a UV ballast water treatment system, required under the Ballast Water Management Convention, to prevent the spread of marine pests between ports. Ballast water passes through massive filters and ultraviolet chambers, neutralising microorganisms before discharge.

Bluebridge Ferry, Livia uses a UV ballast water treatment system, required under the Ballast Water Management Convention, to prevent the spread of marine pests between ports. // Photo credit: Kirsten Thomas / Boating New Zealand

“It’s one of the best systems we can use,” says Joe. “Efficient, clean, and fully compliant.”

Cool running: heat management and purification

All that horsepower needs cooling. The engine jacket water circulates through a dedicated cooling room, where seawater is pumped through massive heat exchangers.

“In winter operations, think Italian, not Wellington, they can blend warm water from a vertical water chest to avoid freezing,” Joe explains.

Cooling is a must-have. Bluebridge Ferry, Livia’s engine jacket water circulates through a dedicated cooling room, where seawater is pumped through massive heat exchangers. // Photo credit: Kirsten Thomas / Boating New Zealand

Cybersecurity and remote ops

Bluebridge isn’t just about steel and grease. Behind the engine room doors lies serious digital protection. The ship will soon be secured by DarkTrace, an AI-driven cybersecurity system that monitors for anomalies and can shut down any suspicious activity on the operational technology side.

- Advertisement, article continues below -

The bridge of Bluebridge’s newest ferry, Livia // Photo credit: Kirsten Thomas / Boating New Zealand

As the maritime industry evolves, these systems are no longer nice-to-haves: they’re essential.

“We’ve already seen where the future’s going,” says Joe. “Automation, AI, secure control. But the key is still manual resilience, you’ve got to be able to take over.”

Stabilisation, safety, and seakeeping

In the Cook Strait, comfort is king. The vessel uses gyro-controlled active stabiliser fins deployed near midships to minimise roll. It’s the same principle as on smaller boats, but scaled up.

Despite their effectiveness, the gyro is surprisingly compact, about 10cm in diameter in the core unit, suspended in fluid. The fins doing the word are not so trivial, several metres long, even still, they are agile for their size!

“Even the biggest boat needs the smallest O-ring.” and that’s what this mechanic is doing right now. // Photo credit: Kirsten Thomas / Boating New Zealand

A ship made to last

From the boiler room to the crankcase, this ferry is a masterclass in pragmatic engineering. There’s no flash, just function, and a lot of it.

“She’s got enough redundancy, simplicity, and robustness to serve Cook Strait well into the 2030s,” Joe says.

We believe him. This was one of the most detailed tours we’ve ever received.

// Photo credit: Kirsten Thomas / Boating New Zealand

Special thanks to First Officer Joe and Bluebridge’s Chief Operating Officer Will Dady for granting Boating New Zealand full access and walking us through this impressive vessel.

1 of 10