{"id":100076,"date":"2026-04-30T01:57:40","date_gmt":"2026-04-30T01:57:40","guid":{"rendered":"https:\/\/irwindevc.wpenginepowered.com\/?page_id=100076"},"modified":"2026-06-16T06:48:34","modified_gmt":"2026-06-16T06:48:34","slug":"zhoushan-dn800-pipe-project","status":"publish","type":"page","link":"https:\/\/irlservice.com\/en\/case-studies\/zhoushan-dn800-pipe-project\/","title":{"rendered":"Zhoushan Dock \u2014 DN800 Large-Bore Pipe Project"},"content":{"rendered":"<div class=\"et_pb_section_0 et_pb_section et_section_regular et_block_section\">\n<div class=\"et_pb_row_0 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_0 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_tablet et_flex_column_24_24_phone et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_module et_pb_button_module_wrapper et_pb_button_0_wrapper\"><a class=\"et_pb_button_0 et_pb_button et_pb_bg_layout_dark et_pb_module et_flex_module\" href=\"https:\/\/irlservice.com\/en\/case-studies\/\" data-icon=\"#\">Return to case list<\/a><\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_row_1 et_pb_row et_flex_row preset--module--divi-row--5138c454-be54-4233-bd3b-f8e6a8747976\">\n<div class=\"et_pb_column_1 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_tablet et_flex_column_24_24_phone et_flex_column_24_24_ultraWide preset--module--divi-column--73121f80-a3ef-4484-8763-c3f18e3c56d2\">\n<div class=\"et_pb_heading_0 et_pb_heading et_pb_module et_flex_module preset--module--divi-heading--ddeb8c09-9078-4424-bc15-2efb6572e28e\"><div class=\"et_pb_heading_container\"><h1 class=\"et_pb_module_header\">Zhoushan Dock \u2014 DN800 Large-Bore Pipe Project<\/h1><\/div><\/div>\n\n<div class=\"et_pb_blurb_0 et_pb_blurb et_pb_bg_layout_light et_pb_blurb_position_left et_pb_module et_flex_module\"><div class=\"et_pb_blurb_content et_flex_module\"><div class=\"et_pb_main_blurb_image\"><span class=\"et_pb_image_wrap\"><span class=\"et-pb-icon\">\ue08a<\/span><\/span><\/div><div class=\"et_pb_blurb_container\"><div class=\"et_pb_blurb_description\"><p>Client \/<span>A ship-repair yard in Zhoushan<\/span><\/p>\n<\/div><\/div><\/div><\/div>\n\n<div class=\"et_pb_blurb_1 et_pb_blurb et_pb_bg_layout_light et_pb_blurb_position_left et_pb_module et_flex_module\"><div class=\"et_pb_blurb_content et_flex_module\"><div class=\"et_pb_main_blurb_image\"><span class=\"et_pb_image_wrap\"><span class=\"et-pb-icon\">\uf3c5<\/span><\/span><\/div><div class=\"et_pb_blurb_container\"><div class=\"et_pb_blurb_description\"><p>Location \/<span>Zhoushan (survey &amp; installation), Shenzhen (manufacture)<\/span><\/p>\n<\/div><\/div><\/div><\/div>\n\n<div class=\"et_pb_blurb_2 et_pb_blurb et_pb_bg_layout_light et_pb_blurb_position_left et_pb_module et_flex_module\"><div class=\"et_pb_blurb_content et_flex_module\"><div class=\"et_pb_main_blurb_image\"><span class=\"et_pb_image_wrap\"><span class=\"et-pb-icon\">\uf073<\/span><\/span><\/div><div class=\"et_pb_blurb_container\"><div class=\"et_pb_blurb_description\"><p>Date \/<span>2025<\/span><\/p>\n<\/div><\/div><\/div><\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_row_2 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_2 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_tablet et_flex_column_24_24_phone et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_sidebar_0 et_pb_widget_area clearfix et_pb_widget_area_right et_pb_bg_layout_light et_pb_sidebar_no_border et_pb_module et_flex_module\"><\/div>\n<\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_section_1 et_pb_section et_section_regular et_flex_section\">\n<div class=\"et_pb_row_3 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_3 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_tablet 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0.8rem;\n        color: #6A7D8E;\n        margin-top: 0.6rem;\n        text-align: center;\n        max-width: 80%;\n        margin-left: auto;\n        margin-right: auto;\n    }\n    @media (max-width: 700px) {\n        #irwin-zhoushan-case .section-title { font-size: 1.4rem; }\n        #irwin-zhoushan-case .title-main h1 { font-size: 1.5rem; }\n        #irwin-zhoushan-case .case-image { max-width: 85%; }\n        #irwin-zhoushan-case .image-caption { max-width: 95%; }\n    }\n<\/style>\n\n<!-- \u6807\u9898\u533a -->\n<div class=\"title-main\">\n    <h2>A Zhoushan ship-repair yard \u00b7 DN800 large-bore seawater-pipe replacement<\/h2>\n    <div class=\"subhead\">Zhoushan, China | complex DN800 large-bore pipe | no old-pipe removal \u00b7 digital twin \u00b7 first-time installation<\/div>\n<\/div>\n\n<!-- \u73b0\u573a\u56fe\u7247\uff08\u5355\u5f20\u5c45\u4e2d\uff09 -->\n<div class=\"image-container\">\n    <img decoding=\"async\" class=\"case-image\" \n         src=\"https:\/\/irlservice.com\/wp-content\/uploads\/2026\/05\/be082f51c7551c784386bfeda9aadd55-scaled.jpg\" \n         alt=\"\u821f\u5c71\u8239\u5382DN800\u6d77\u6c34\u4e3b\u7ba1\u8def\u73b0\u573a\">\n    <div class=\"image-caption\">\n        On site at a Zhoushan ship-repair yard: DN800 large-bore seawater pipe with flanges, elbows and reducing branches \u2014 the traditional method would require removing and copying the old pipe\n    <\/div>\n<\/div>\n\n<!-- \u9879\u76ee\u80cc\u666f -->\n<div class=\"section\">\n    <h2 class=\"section-title\">Project Background<\/h2>\n    <p>A large vessel under repair at a Zhoushan ship-repair yard needed three seawater main lines replaced \u2014 DN800 bore, about 25 m total, with 10 flanges, 6 elbows and 3 DN600 reducing branches. By the yard's traditional method, pipe this large and complex would have to be removed whole and copied section by section in an onshore workshop as a template \u2014 slow, labour-intensive, and the removal itself risks some damage to the hull structure.<\/p>\n<\/div>\n\n<!-- \u6311\u6218\u4e0e\u9700\u6c42 -->\n<div class=\"section\">\n    <h2 class=\"section-title\">Challenges &amp; Requirements<\/h2>\n    <p>The core difficulty: the old pipe could not be removed to serve as a copying template. On one hand, Chinese customs tightly controls landing used pipe from foreign vessels; on the other, neither owner nor yard wanted the extra time and hull-damage risk of removal. The yard had never before made pipe this large and geometrically complex from a purely digital survey, and doubted whether the dimensions could be right first time.<\/p>\n    <div class=\"highlight-box\">\n        <p style=\"margin-bottom:0; font-weight:500;\">Core need: zero old-pipe removal, zero on-site trimming, 100% digitally prefabricated installation<\/p>\n    <\/div>\n<\/div>\n\n<!-- Irwin \u89e3\u51b3\u65b9\u6848 -->\n<div class=\"section\">\n    <h2 class=\"section-title\">The Irwin Solution<\/h2>\n    <p>While the vessel was berthed in Zhoushan, the Irwin team boarded and scanned the three in-service DN800 lines directly with Automet, building an as-built digital twin. The workshop laid out and cut the spools to the digital model, using the Automet FAB system to verify dimensions at the tack-weld stage \u2014 keeping overall dimensions, including gasket and coating allowances, within PFI-ES3 tolerance of the digital twin. After welding, Automet verification was repeated to confirm no weld distortion before PE lining and external coating.<\/p>\n<\/div>\n\n<!-- \u5de5\u827a\u6d41\u7a0b -->\n<div class=\"section\">\n    <h2 class=\"section-title\">Process<\/h2>\n    <div class=\"steps-wrap\">\n        <div class=\"step\"><strong>3D scan of in-service pipe<\/strong>Direct Automet scan, with no old-pipe removal<\/div>\n        <div class=\"step\"><strong>As-built digital twin<\/strong>Generating isometrics and manufacturing drawings<\/div>\n        <div class=\"step\"><strong>\u2702\ufe0f Workshop cutting &amp; tack-welding<\/strong>CNC cutting and assembly to the digital model<\/div>\n        <div class=\"step\"><strong>\u2705 First Automet verification<\/strong>Dimensional re-check at tack-weld stage (including gasket and coating allowances)<\/div>\n        <div class=\"step\"><strong>Final welding<\/strong>TIG + FCAW procedure, controlling weld distortion<\/div>\n        <div class=\"step\"><strong>Post-weld Automet verification<\/strong>Confirming no distortion and meeting PFI-ES3 tolerance<\/div>\n        <div class=\"step\"><strong>Rotary PE lining<\/strong>Applying a fully sealed corrosion barrier<\/div>\n        <div class=\"step\"><strong>External coating<\/strong>Blast-cleaning + industrial epoxy<\/div>\n        <div class=\"step\"><strong>Final QC<\/strong>Pressure test &amp; dimensional re-check<\/div>\n        <div class=\"step\"><strong>Installation at the yard<\/strong>Lifted and connected directly, with no on-site trimming<\/div>\n    <\/div>\n<\/div>\n\n<!-- \u9879\u76ee\u6210\u679c -->\n<div class=\"section\">\n    <h2 class=\"section-title\">Results<\/h2>\n    <div class=\"results-grid\">\n        <div class=\"result-card\"><div class=\"result-num\">100%<\/div><div><strong>First-time installation<\/strong><\/div><p>All three large-bore spools fitted first time, with no on-site trimming or rework<\/p><\/div>\n        <div class=\"result-card\"><div class=\"result-num\">Zero hot work<\/div><div><strong>Workshop prefabricated<\/strong><\/div><p>The yard's first pipe replacement with zero on-site hot work \u2014 all fabrication done in the workshop<\/p><\/div>\n        <div class=\"result-card\"><div class=\"result-num\">No old-pipe removal<\/div><div><strong>Risk avoided<\/strong><\/div><p>Completely avoided hull-structure damage and customs-compliance risk<\/p><\/div>\n        <div class=\"result-card\"><div class=\"result-num\">\u221267%<\/div><div><strong>Installation time cut<\/strong><\/div><p>Installation time cut to a third of the traditional method, greatly reducing dock occupancy<\/p><\/div>\n    <\/div>\n    <div class=\"highlight-box\">\n        <p>\u2705 <strong>100% first-time installation<\/strong> \u2014 all three large-bore spools fitted first time, with no on-site trimming or rework.<br>\n        \u2705 <strong>Zero on-site hot work<\/strong> \u2014 the yard's first pipe replacement needing no on-site welding or cutting.<br>\n        \u2705 <strong>No old-pipe removal<\/strong> \u2014 avoiding hull damage and customs-compliance risk.<br>\n        \u2705 <strong>Installation time cut 67%<\/strong> \u2014 greatly reducing dock-occupancy cost.<\/p>\n    <\/div>\n<\/div>\n\n<!-- \u5ba2\u6237\u4ef7\u503c -->\n<div class=\"section\">\n    <h2 class=\"section-title\">Client Value<\/h2>\n    <p>For the Zhoushan ship-repair yard, the project meant more than a successful pipe replacement \u2014 it was a shift in working philosophy. The yard experienced for the first time the efficiency and quality assurance of the \"digital twin + centralised prefabrication\" model, overturning the old belief that complex large-bore pipe must be copied from the removed original. The yard has since actively recommended Irwin's prefabricated approach on several later repair projects.<\/p>\n    <div class=\"quote\">\n        \"The yard now actively recommends Irwin's prefabricated approach on later repair projects \u2014 digital-twin technology has set a new benchmark for ship repair.\"\n    <\/div>\n<\/div>\n\n<hr>\n<div style=\"font-size:0.8rem; text-align:center; color:#5c7c8a; padding:0.2rem 0 0.5rem;\">\n    ? \u9879\u76ee\u6267\u884c\u8303\u56f4\uff1a\u821f\u5c71(\u6d4b\u91cf) \u2192 \u6df1\u5733(\u5236\u9020) \u2192 \u821f\u5c71(\u5b89\u88c5) | Automet\u00ae \u6570\u5b57\u5b6a\u751f | DN800 \u590d\u6742\u7ba1\u8def\u4e00\u6b21\u901a\u8fc7\n<\/div>\n<div class=\"footer-note\">\n    \u00a9 Irwin Industrial Solutions \u2014 specialists in piping for highly corrosive marine environments | 100% prefabricated delivery \u00b7 no old-pipe removal \u00b7 trusted by yards worldwide\n<\/div>\n<\/div><\/div><\/div>\n<\/div>\n<\/div>\n\n<div class=\"et_pb_row_4 et_pb_row et_flex_row\">\n<div class=\"et_pb_column_4 et_pb_column et-last-child et_flex_column et_pb_css_mix_blend_mode_passthrough et_flex_column_24_24 et_flex_column_24_24_tablet et_flex_column_24_24_phone et_flex_column_24_24_ultraWide\">\n<div class=\"et_pb_code_1 et_pb_code et_pb_module\"><div class=\"et_pb_code_inner\"><div class=\"hover-case-nav\">\n  <style>\n    .hover-case-nav {\n      position: fixed;\n      right: 0;\n      top: 25%;\n      transform: translateY(-50%);\n      z-index: 1000;\n      font-family: system-ui, -apple-system, 'Segoe UI', Roboto, sans-serif;\n    }\n    \/* \u89e6\u53d1\u5668\uff08\u7ad6\u5411\u6309\u94ae\uff09 *\/\n    .nav-trigger {\n      writing-mode: vertical-rl;\n      text-orientation: mixed;\n      background: #0B3B4A;\n      color: white;\n      padding: 1rem 0.5rem;\n      border-radius: 0.75rem 0 0 0.75rem;\n      font-size: 0.9rem;\n      font-weight: 600;\n      letter-spacing: 2px;\n      cursor: default;\n      transition: all 0.2s;\n      box-shadow: -2px 2px 8px rgba(0,0,0,0.1);\n    }\n    .nav-trigger:hover {\n      background: #4A90A4;\n      padding-right: 0.8rem;\n    }\n    \/* \u4fa7\u8fb9\u680f\u4e3b\u4f53 *\/\n    .nav-content {\n      position: absolute;\n      top: 50%;\n      transform: translateY(-50%);\n      right: 40px;\n      width: 260px;\n      background: #ffffff;\n      border-radius: 1rem;\n      box-shadow: 0 10px 25px -5px rgba(0,0,0,0.15);\n      border: 1px solid #e2e8f0;\n      padding: 0.8rem 0.7rem; 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