ASME U & S Stamp ISO 9001 Certified

Boiler Headers Engineered for Performance

Custom superheater, reheater, economizer and water wall headers for power plants, waste-to-energy facilities and industrial boilers. P91/P92 alloy expertise with full code compliance.

Get Header Quote Technical Specs

ASME Certified

EN Standards

Years Est.

500+

Headers Delivered

30+

Export Countries

Header Types:

Superheater Reheater Water Wall Economizer

Manufacturing Excellence

Precision Boiler Header Fabrication

Product Range

Complete Boiler Header Solutions

From water wall headers to high-temperature superheater manifolds, we engineer and manufacture headers for every boiler application with materials ranging from carbon steel to advanced P91/P92 alloys.

Superheater Headers

High-temperature steam collection headers for primary and secondary superheaters. P91/P92 materials for 540-600°C operation.

• Primary & Secondary SH Headers
• Attemperator Integration
• P91/P92 Alloy Construction

Reheater Headers

Inlet and outlet headers for steam reheating circuits. Designed for thermal cycling and pressure fluctuations.

Cold & Hot RH Headers
Thermal Expansion Design
P22/P91 Material Options

Water Wall Headers

Top and bottom distribution headers for water wall panels. Optimized flow distribution and thermal performance.

• Top & Bottom WW Headers
• Downcomer Connections
• SA106B/P265GH Materials

Economizer Headers

Feedwater inlet and outlet headers for economizer sections. Corrosion-resistant materials for extended service life.

• Feedwater Distribution
• Corrosion Allowance Design
• SA106B/16Mo3 Options

Manufacturing Excellence

Why Choose ORL for Boiler Headers?

16 years of specialized experience in boiler pressure parts manufacturing with comprehensive quality systems and global project experience.

Expert Engineering Team

Senior engineers with 20+ years in boiler header design. Comprehensive understanding of ASME, EN and GB codes with expertise in P91/P92 high-temperature applications.

Certified Quality Systems

ASME U & S Stamp, ISO 9001:2015 and EN 1090 certified. Complete in-house NDT capabilities with third-party inspection support from TÜV, BV, SGS and other recognized bodies.

Global Project Experience

Successfully delivered headers to 30+ countries for power plants, waste-to-energy facilities and industrial applications. Expert logistics support from Shanghai port.

500+

Headers Delivered

30+

Export Countries

Years Established

12h

Response Time

Industry Applications

Proven Performance Across Industries

Our boiler headers serve critical applications in power generation, waste-to-energy, biomass and industrial steam systems worldwide.

Power Generation

High-pressure superheater and reheater headers for CFB, coal-fired and gas-fired power plants up to 600MW capacity.

• Design pressure: 18-30 MPa
• Steam temperature: 540-600°C
• Materials: P91/P92 alloy steels

Waste-to-Energy

Corrosion-resistant headers for municipal solid waste and biomass boiler systems with enhanced material specifications.

• Corrosion allowance: 3-6mm
• Enhanced alloy options available
• Design life: 25+ years

Industrial Steam

Custom header manifolds for chemical, petrochemical, sugar mills and general industrial steam applications.

• Pressure range: 4-16 MPa
• Flexible connection arrangements
• Fast-track delivery available

Manufacturing Process

From Design to Delivery

Our comprehensive manufacturing process ensures every header meets the highest quality standards and project requirements.

Design Review

Engineering analysis of header drawings, process data and code requirements within 24 hours.

Material Procurement

Certified material sourcing with full traceability and MTC 3.1 documentation.

Fabrication

Precision machining, welding and heat treatment with qualified procedures and certified welders.

Quality Control

Complete NDT testing, pressure testing and dimensional inspection with third-party witness support.

Export Delivery

Professional packaging, export documentation and logistics coordination from Shanghai port.

Technical Specifications

Boiler Header Design Capabilities

Comprehensive design and manufacturing capabilities for all types of boiler headers with materials from carbon steel to advanced P91/P92 alloys.

Design Capabilities

Parameter	Range	Notes
Header Diameter	200-2000mm	Larger sizes available
Wall Thickness	10-100mm	Per code calculations
Design Pressure	Up to 30MPa	Project specific
Design Temperature	Up to 650°C	Material dependent
Header Length	1-20 meters	Modular design available
Tube Connections	10-500+ tubes	Welded or expanded

Material Options

Carbon & Low Alloy Steels

• SA106B, SA106C for water headers

• P235GH, P265GH, 16Mo3 per EN standards

• 20G, 20MnG per GB standards

Medium Alloy Steels

• SA335 P11, P12, P22 for moderate temperature

• 12Cr1MoV, 15CrMo per GB standards

High-Temperature Alloys

• SA335 P91, P92 for superheater/reheater

• 12Cr1MoVG, T91 equivalent materials

• Special alloys for corrosive environments

Design Standards

ASME Codes

Section I, VIII Division 1 & 2

EN Standards

EN 12952, EN 13445

GB Standards

GB 5310, GB 150 series

Frequently Asked Questions

Boiler Header Engineering FAQ

Expert answers to the most critical questions from boiler designers, EPC contractors and power plant engineers about boiler header design and manufacturing.

What types of boiler headers can ORL Power manufacture?

ORL Power manufactures all types of boiler headers for power generation and industrial applications:

Steam Headers:

Superheater outlet headers (primary & secondary)
Reheater inlet and outlet headers
Steam distribution manifolds
High-temperature headers up to 650°C

Water Headers:

Water wall top and bottom headers
Economizer inlet and outlet headers
Downcomer connection headers
Feedwater distribution manifolds

All headers are custom-designed to match your specific boiler layout, tube arrangement and operating conditions.

Which design codes and standards can your headers comply with?

Our headers can be designed and manufactured to comply with major international codes:

ASME Codes:

ASME Section I (Power Boilers)
ASME Section VIII Div. 1 & 2
ASME U & S Stamp certification

European Standards:

EN 12952 (Water-tube boilers)
EN 13445 (Pressure vessels)
PED 2014/68/EU compliance

Chinese Standards:

GB 5310 (Boiler steel tubes)
GB 150 (Pressure vessels)
JB/T 4730 (NDT standards)

We provide complete design calculations, mechanical drawings and inspection documentation according to the selected code.

What material grades can you supply for high-temperature boiler headers?

We supply a comprehensive range of materials for different temperature and pressure conditions:

Material Grade	Max Temperature	Typical Application
SA106B / P235GH	450°C	Water wall, economizer headers
SA335 P22 / 10CrMo9-10	540°C	Low-temp superheater, reheater
SA335 P91 / X10CrMoVNb9-1	600°C	High-temp superheater, reheater
SA335 P92	650°C	Advanced USC applications

All materials come with certified MTCs (EN 10204 3.1) and full traceability documentation. We have extensive experience with P91/P92 welding procedures and post-weld heat treatment.

Can you manufacture replacement headers for existing boilers?

Yes, ORL Power regularly supplies replacement headers for existing boilers, including situations where original OEM support is no longer available.

We can work with:

Original OEM drawings and specifications
Site measurements and sketches when drawings are unavailable
Sample headers for reverse engineering
Partial information supplemented by our engineering experience

Value-added improvements:

Material upgrades for enhanced corrosion/erosion resistance
Improved nozzle layouts for better maintenance access
Enhanced design margins while maintaining compatibility
Updated welding procedures for improved reliability

Our engineering team can analyze your existing system and propose improvements while ensuring full compatibility with existing boiler connections.

What quality control and documentation do you provide?

Material Control:

Certified material test reports (MTC 3.1)
Positive material identification (PMI)
Complete traceability from raw material to finished header
Chemical composition and mechanical property verification

Welding & NDT:

Qualified WPS/PQR and certified welders
Radiographic testing of main butt welds
Ultrasonic testing where specified
MT/PT for fillet welds and surface examinations

Testing & Inspection:

Hydrostatic pressure testing per applicable code
Dimensional inspection reports
Hardness testing for P91/P92 materials
Third-party inspection witness (TÜV, BV, SGS, etc.)

Documentation Package:

Complete manufacturing dossier
Test certificates and inspection reports
Welding procedure specifications
Export and shipping documentation

What information do you need for a boiler header quotation?

To provide an accurate quotation and technical proposal, we typically need the following information:

Process & Design Data:

Header function (superheater, reheater, water wall, economizer)
Design pressure and temperature
Operating pressure and temperature
Fluid type (water, steam, steam/water mixture)
Required design code (ASME, EN, GB)

Geometry & Configuration:

Header diameter and wall thickness (if known)
Header length and orientation
Number of tube connections and tube sizes
Nozzle sizes and locations
Support and attachment requirements

Optional but helpful: Existing drawings, sketches, photos of similar headers, project timeline and delivery requirements.

Send your inquiry to international@orlpower.com and our engineers will respond within 12 hours with technical questions and preliminary recommendations.

How are boiler headers packaged and shipped for international projects?

Export Packaging:

All header ends and nozzles are capped and sealed
Headers secured on steel or wooden saddles
Protective coating for sea transport
Moisture protection and corrosion prevention
Compliance with ISPM-15 fumigation requirements

Documentation & Logistics:

Clear marking with item numbers and weights
Center of gravity marking for lifting
Detailed packing lists and shipping instructions
Export documentation and certificates
Professional logistics support from Shanghai port

Typical shipping options include sea freight (most economical), air freight (for urgent deliveries), and multimodal transport. We work with experienced freight forwarders to ensure safe delivery to your project site.

What is your typical lead time for boiler header manufacturing?

Lead times vary based on header complexity, material requirements and current production schedule:

Header Type	Typical Lead Time	Factors Affecting Timeline
Standard carbon steel headers	8-12 weeks	Size, complexity, quantity
Alloy steel (P22) headers	10-14 weeks	Material availability, PWHT requirements
P91/P92 high-temp headers	12-16 weeks	Special welding procedures, extended PWHT
Large/complex manifolds	14-20 weeks	Engineering time, fabrication complexity

Expedited delivery: For urgent shutdown projects, we can often accommodate accelerated schedules with additional resources. Contact us early in your planning process for best results.

Project planning: We recommend initiating header procurement 6-8 months before your planned outage to allow adequate time for engineering, manufacturing and logistics.

Ready to Discuss Your Boiler Header Project?

Send us your header requirements and get expert engineering consultation from our experienced team. Fast response guaranteed.

Get In Touch

international@orlpower.com

Website

www.orlpower.com

Location

Suzhou, Jiangsu, China

Why Choose ORL Power?

16 years specialized in boiler pressure parts

ASME U & S Stamp certified manufacturer

500+ headers delivered to 30+ countries

Expert P91/P92 high-temperature capabilities

Request Header Quote

Typical response time: 12 hours | Free technical consultation

ASME U & S Stamp Certified

ISO 9001:2015 Quality System

Established 2009 | 500+ Headers Delivered

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