Product Description

A steam header, also known as a boiler manifold header or steam distribution header, is a large-diameter pressure vessel component that serves as the central collection and distribution point for steam and water within a boiler system. It is typically fabricated from seamless steel pipes with welded flat end covers and features multiple tube stubs or nozzles that connect to various tube bundles. The header functions to collect steam from generating tubes, mix working fluids to ensure uniform heating, and redistribute them to downstream pipelines. Depending on their location in the boiler, headers are classified as upper and lower headers, or inlet and outlet headers, and by the type of bundles they collect, they can be further divided into water wall headers, superheater headers, economizer headers, and others. Operating under pressures ranging from 300 psi to over 2,000 psi, steam headers are critical pressure parts that demand the highest standards of design and fabrication.

Parameter

Application description

Steam headers are indispensable components across a wide spectrum of industrial and power generation applications. In power generation plants, they distribute high-pressure steam from boilers to turbines and auxiliary systems. In the petrochemical and chemical industries, they provide reliable steam flow for process heating and thermal management. They are also extensively used in iron and steel production, cement manufacturing, food and beverage processing, and various manufacturing facilities where steam is required for production processes. Additionally, headers play a vital role in circulating fluidized bed boilers, heat recovery steam generators, and industrial boiler systems, serving to collect, mix, and redistribute working fluids while reducing thermal deviation and ensuring uniform heat absorption across all tubes. Their ability to connect different sections of the boiler with varying pipe sizes and layouts makes them essential for maintaining smooth and efficient fluid flow throughout the entire system.

Production description

Our steam headers are manufactured following a rigorous and comprehensive production process to ensure the highest quality and reliability. The workflow begins with raw material inspection, followed by ingot forming, hot or cold rolling, and heat treatment such as normalizing and tempering to achieve the desired mechanical properties. Precision drilling creates the required openings, after which tube stubs are carefully welded to the header body using advanced submerged arc automatic welding technology, which ensures high manufacturing efficiency, excellent weld quality, a smooth weld appearance, and safe, reliable operation. All welded joints undergo one hundred percent non-destructive examination including radiographic testing, penetrant testing, and ultrasonic testing as required, followed by post-weld heat treatment for stress relief, a hydraulic pressure test at design pressure to verify leak-tight integrity, and final surface coating. Our manufacturing complies with international standards including ASME Section I, ISO 3834, and GB/T 16507, with materials available in carbon steel grades such as 20G and SA-106B/C, alloy steel grades such as 15CrMoG, 12Cr1MoVG, and SA-335P12/P22, as well as advanced grades like SA-335P91, P92, and P122 for ultra-supercritical applications.

Shipping Packaging

Each steam header is carefully packaged to ensure safe transit and storage, particularly for international export shipments. For oversized cargo such as extra-long, overwidth, or overweight headers, we utilize reinforced frame boxes designed for easy handling and secure transport, while standard-sized headers are shipped in ordinary containers with all items properly reinforced and braced after loading to prevent movement during transit. All packaging is sea-worthy and export-grade, featuring protective padding to prevent surface damage, waterproof and moisture-proof wrapping for corrosion protection, and clear shipping marks, lifting points, and handling instructions attached to each package. This comprehensive packaging approach ensures that your steam headers arrive at the destination site in perfect condition, ready for efficient unloading and installation.

Why Choose Us?

1.ASME & ISO Certified: All headers manufactured to strict international quality and safety standards.

2.Fully Customizable: Diameters, wall thicknesses, materials, and nozzle layouts tailored to your exact boiler design.

3.Advanced Welding & 100% NDE: Submerged arc welding with comprehensive RT, PT, and UT testing ensures flawless, pressure-tight joints.

4.Specialized in High-Grade Alloys: Extensive experience with heat‑resistant materials like P91, P92, and P122 for ultra-supercritical applications.

5.On-Time Delivery & Secure Packaging: Reliable shipping schedules with export‑grade packing to protect oversized headers during transit.

FAQ

1.Can you customize headers to match our specific boiler design and operating parameters?
Yes, we offer full customization. Outside diameters, wall thicknesses, material grades, overall lengths, and nozzle quantities and arrangements are all tailored to your engineering drawings. We also design to your specified pressure and temperature requirements.

2.What quality standards and testing do you apply?
Our headers comply with ASME Section I, ISO 3834, and GB/T 16507. Each unit undergoes 100% nondestructive examination (RT, PT, UT as required), a hydrostatic pressure test, and postweld heat treatment when specified. All materials are traceable with mill test certificates.

3.How do you handle packaging and delivery for large headers?
For oversized headers, we use reinforced frame boxes with protective padding and secure strapping. Standard sizes are shipped in containers with proper bracing. All packaging is waterproof, exportgrade, and clearly marked with handling instructions. Lead times typically range from 45 to 90 days depending on specifications and order size.