GB/ASME/EN Code Compliant • ISO Certified Since 2009

Boiler Headers for Power & Industrial Boilers

Custom-designed superheater, reheater, water wall and economizer headers using advanced P91, P22 and SA-516 materials for critical boiler applications.

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P91 Boiler Header

ASME Certified Fabrication

Why Choose ORL for Boiler Headers?

Specialized boiler pressure parts manufacturer established in 2009

Senior Engineering Team

Our engineers bring 20+ years of experience in boiler header and pressure parts design, with expertise in code calculations and layout optimization for complex tube arrangements.

Seamless Communication

Dedicated English-speaking project engineers respond within 12 hours, ensuring clear technical discussions on header materials, welding, NDT and inspection requirements.

Full-Service Support

From drawing review, material procurement, header fabrication, NDT testing to export packaging – we manage every step so your boiler project stays on schedule.

Certified Quality System

ASME U & S Stamp, ISO 9001 and EN 1090 certified. Complete in-house NDT capabilities with third-party inspection available upon request.

500+

Boiler Headers Delivered

30+

Export Countries

Years Established

Since 2009

12h

Typical Response Time

Proven Performance Across Industries

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

Power Generation Headers

High-pressure superheater and reheater headers for 300MW+ CFB and coal-fired power plants.

• Typical operating pressure: 18–25 MPa (case-by-case design)
• Steam temperature: 540–600°C
• Materials: P91 / P92 alloy steels

Waste-to-Energy Headers

Corrosion-resistant headers for municipal solid waste and waste-to-energy boiler systems.

• Design corrosion allowance: 3–6 mm (depending on flue gas composition)
• Material options: SA-213 T22 with overlay or enhanced alloys
• Design service life: up to 25+ years under proper operation

Industrial Steam Headers

Custom header manifolds for chemical, petrochemical and general industrial plants.

• Pressure range: approx. 4–16 MPa
• Flexible tube size and connection arrangements
• Fast-track delivery available for shutdown projects

Worry-Free Boiler Header Collaboration

Our experienced team manages every detail of your boiler header project so you can focus on core engineering and site work.

Drawing & Data Review

Engineers analyze your header drawings and basic process data within 24 hours.

Technical Discussion

Clear communication on design codes, material grades, welding procedures and NDT coverage.

Header Fabrication

Controlled production with qualified welders, heat treatment and dimensional checks.

Inspection & Documentation

Complete MTRs, NDT reports, hydrotest records and inspection certificates before shipment.

Export Logistics

Professional packaging, marking and export documentation from Shanghai port.

"ORL's engineering team brought valuable expertise to our CFB boiler header replacement project. Their senior engineers reviewed our original OEM drawings and proposed optimization suggestions that prevented potential fabrication and installation issues. Regular progress updates and responsive communication gave us full confidence throughout production."

– Project Manager, 350MW Power Plant, Southeast Asia

Boiler Header Engineering FAQ

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

01
What Are Boiler Headers and Where Are They Used?

Boiler headers are cylindrical pressure parts that collect, mix and redistribute water or steam between different tube banks in a boiler. They act as critical junction points where multiple tubes are connected, ensuring proper flow distribution and pressure control across the boiler circuit.

Typical Header Positions:

• Water wall inlet / outlet headers
• Economizer inlet / outlet headers
• Superheater and reheater inlet / outlet headers
• Downcomer and circulation headers
• Special distribution manifolds for industrial steam systems

02
What Types of Boiler Headers Can ORL Power Manufacture?

Water Headers

Headers for water circulation and feedwater distribution.

• Water wall top & bottom headers
• Downcomer connection headers
• Economizer inlet headers

Steam Headers

Headers for saturated and superheated steam collection and distribution.

• Superheater outlet headers
• Reheater inlet / outlet headers
• Industrial steam distribution manifolds

Custom Manifolds

Special configurations for retrofits and space-limited layouts.

• Multi-row tube manifolds
• Corner headers and transition pieces
• Replacement headers for existing boilers

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

03
Which Design Codes and Standards Can Your Headers Comply With?

Design Codes:

• ASME Boiler and Pressure Vessel Code (e.g. Section I / Section VIII)
• EN standards for water-tube boilers and pressure vessels (e.g. EN 12952, EN 13445)
• GB / GB-T Chinese standards (e.g. GB 5310, GB 150 series)

The applicable code will be selected according to project location, client requirements and boiler classification.

What We Provide:

Mechanical Calculations

Wall thickness and reinforcement calculations for headers and branch connections.

Design Documentation

General arrangement drawings, nozzle layout, welding details and bill of materials.

Inspection Plan

Inspection & Test Plan (ITP) aligned with the selected design code and client QA requirements.

04
What Material Grades Can You Supply for Boiler Headers?

Typical Material Range:

• Carbon & low alloy steels: SA106B, P235GH, P265GH, 16Mo3, 20G
• Medium alloy steels: SA335 P11, P12, P22
• High-temperature alloys: SA335 P91, P92, 15CrMoG, 12Cr1MoVG

Material selection is based on design pressure, design temperature, fluid type and expected service life.

High-Temperature Headers:

For superheater and reheater headers working at high temperature, we can supply P91 / P92 and other creep-resistant alloys with qualified welding and post weld heat treatment procedures.

• PWHT procedures for P91/P92 headers
• Hardness and impact testing as per code
• Traceable material certificates (MTC 3.1)

05
What Information Do You Need to Engineer a Boiler Header?

To quickly evaluate your header requirements and propose a suitable solution, we usually ask for the following basic data:

Process & Design Data:

• Header function and medium (water, saturated steam, superheated steam)
• Design pressure and design temperature (and/or working values)
• Boiler type and location in the system (water wall, economizer, superheater, etc.)

Geometry & Standards:

• Desired header OD, wall thickness and length (if available)
• Tube size, number of tubes and approximate arrangement
• Required design code (ASME / EN / GB) and preferred material grades

You can send this information together with any existing drawings or photos to orl@orlpoower.com, and our engineers will review and respond with technical suggestions.

06
Can You Manufacture Replacement Headers for Existing Boilers?

Yes. ORL regularly supplies replacement headers for existing boilers, including CFB boilers, coal-fired units, biomass boilers and industrial steam systems.

We Can Work With:

• Original OEM drawings (even if the OEM no longer exists)
• Site measurements and sketches when drawings are not available
• Sample headers provided by the client for reverse engineering

Where appropriate, we can also suggest design improvements such as upgraded materials, improved nozzle layout or enhanced corrosion/erosion allowance while keeping connections compatible with the existing boiler.

07
What Quality Control, NDT and Documentation Are Provided?

Material Control

• Certified material test reports (MTC)
• Positive material identification when required
• Traceability from plate/pipe to finished header

Welding & NDT

• Qualified WPS/PQR and certified welders
• Radiographic and/or ultrasonic testing of main butt welds
• MT/PT for fillet welds and critical areas as required

Pressure Test & Reports

• Hydrostatic test according to applicable code
• Test records, dimensional inspection reports
• Third-party inspection witness available (TÜV, BV, SGS, etc.)

08
How Are Boiler Headers Packaged and Shipped for Export Projects?

Export-Ready Packaging:

• Header ends and all nozzles are capped and protected against dust and moisture.
• Headers are secured on steel or wooden saddles to prevent rolling and deformation.
• External surfaces are coated with suitable corrosion protection for sea transport.

Marking & Documentation:

• Clear marking of item number, project name, weight and center of gravity.
• Packing list, lifting instructions and transport drawings if required.
• Compliance with local packaging regulations (fumigation, ISPM-15, etc.) when specified.

Boiler Header Technical Specifications

Typical design capabilities for ORL Power boiler headers. Final values are confirmed case by case according to design codes and project requirements.

Standard Capability Range

Parameter	Typical Range*	Notes
Header Diameter	200–2000 mm	Larger sizes on request, subject to transport limits
Wall Thickness	10–100 mm	Calculated per ASME/EN/GB code
Design Pressure	Up to 30 MPa	Project-specific verification required
Design Temperature	Up to 650°C	Depends on material grade
Header Length	1–20 meters	Modular design for longer assemblies
Tube Connections	10–500+ tubes	Welded or expanded, per design

*Values shown are for general reference only. Final design limits are confirmed by detailed calculations according to applicable design codes and specific project conditions.

Manufacturing Capabilities

Expert Welding Technology

Automated GTAW, SAW and SMAW processes for header shell and nozzle welding. Welding engineers with extensive experience in P22, P91 and P92 materials.

Precision CNC Machining

Multi-axis CNC centers for accurate tube hole drilling and end machining, typical tolerance within ±0.5 mm for critical dimensions.

Complete NDT Testing

In-house RT, UT, MT and PT with certified technicians. Third-party inspection (TÜV, BV, SGS, LR, etc.) can be arranged upon request.

Flexible Production Planning

Custom project scheduling based on your outage window and construction plan. Typical lead times are provided for reference, with expedited options available for urgent projects.

Need Custom Boiler Headers?

Send us your header drawings or basic process data and get expert engineering consultation for your next boiler project.

Technical Support

[email protected]

Website

www.orlpower.com

Location

Suzhou, Jiangsu, China

Technical Resources

Boiler Header Selection Guide

Boiler Header Technical Data Sheet

Quick Header Quote Request

ASME U & S Stamp Certified

ISO 9001:2015 Quality System

Boiler Pressure Parts Since 2009

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