20G Boiler Superheater System 159mm - 325mm Superheater Header Coil Assembly

Superheater Header & Coil Assembly for Complete Convective Superheater System

The Superheater Header & Coil Assembly is a complete convective superheater system component fabricated by Boyu Heavy Industry, integrating superheater coils with their inlet and outlet distribution headers into a ready-to-install assembly. As an ASME S/U certified boiler component manufacturer with integrated header and coil fabrication capabilities, Boyu produces complete superheater systems that combine CNC-drilled headers, serpentine coils and structural supports into a single assembly. This assembly serves the primary function of distributing steam through the superheater coils and collecting the superheated steam, forming a complete, pressure-tested superheater system that can be installed directly into the boiler convective pass.

The Superheater Header & Coil Assembly is specifically constructed with thick-wall seamless steel headers (OD 159-325mm, WT 16-40mm) CNC-drilled with precise tube connection holes, welded to serpentine superheater coils via full-penetration tube-to-header welds. Boyu fabricates headers from certified materials selected by temperature: 20G (SA-106 Gr.B) carbon steel for low-temperature headers, 15CrMoG (SA-335 P12) for medium-temperature, and 12Cr1MoVG (SA-335 P11/P22) for high-temperature service. The superheater coils are fabricated from matching tube materials (20G/15CrMoG/12Cr1MoVG) with CNC precision bending. The complete assembly includes headers, coils, connecting tubes, support frames and hangers.

Manufactured using CNC header deep-hole drilling, CNC coil bending, robotic tube-to-header welding, post-weld heat treatment (for alloy steel) and comprehensive NDT, every Superheater Header & Coil Assembly undergoes 100% UT for header body and welds, RT for tube-to-header joints, coil bend inspection, dimensional verification and 1.5x design pressure hydraulic test. The ASME S/U certified fabrication ensures compliance with international standards. Boyu's integrated facility enables complete system fabrication under one quality system, eliminating interface risks. Typical delivery is 35-50 days. Full documentation including MTC, WPS/PQR, PWHT reports and NDT records accompanies every shipment.

One significant advantage of Boyu Superheater Header & Coil Assemblies is the complete system integration that reduces on-site installation risk and ensures pressure boundary integrity. By delivering headers, coils and supports as a pre-aligned, pressure-tested assembly, on-site welding and alignment work is reduced by 50-60% compared with separate component delivery. This is particularly valuable for overseas projects. Additionally, the integrated fabrication ensures consistent weld quality across the critical tube-to-header joints, which are subject to both high pressure and high temperature in superheater service.

The Superheater Header & Coil Assembly is adaptable to various boiler types, capacities and steam parameters, making it suitable for power generation, coking, petrochemical, steelmaking, pulp and paper and central heating industries. Its versatility enables complete superheater system fabrication for low-temperature, intermediate and high-temperature stages across boiler pressures from 3.82MPa to 25.4MPa. Furthermore, assemblies can be customized for specific header sizes, coil configurations, tube materials and support designs, ensuring direct compatibility with the boiler convective pass and overall design.

In addition to functional benefits, the Superheater Header & Coil Assembly is designed with safety and long-term reliability in mind. All pressure-bearing components comply with ASME BPVC Section I and GB/T 16507 standards. The integrated support frame design facilitates proper thermal expansion management. Boyu provides technical support for hydraulic calculation, header sizing, thermal expansion analysis and system layout optimization, helping clients achieve complete superheater systems optimized for their specific boiler design.

To summarize, the Boyu Superheater Header & Coil Assembly represents a complete, integrated convective superheater solution leveraging our ASME S/U header fabrication and coil bending expertise. By delivering pre-aligned, pressure-tested complete assemblies with verified weld quality, it reduces on-site installation time, ensures pressure boundary integrity and supports reliable boiler operation. Our integrated manufacturing capability, systematic quality control and expert technical support make this product an ideal choice for boiler manufacturers and EPC contractors.

Features

·        Complete assembly: headers + serpentine coils + supports + hangers integrated

·        ASME S/U certified, 100% UT headers + RT tube-to-header joints + 1.5x hydraulic

·        Header: 20G(SA-106)/15CrMoG(P12)/12Cr1MoVG(P11/P22), OD 159-325mm

·        CNC header deep-hole drilling +/-0.5mm positional tolerance

·        Coil: matching tube material, CNC precision bending, ovality <8%

·        Robotic full-penetration tube-to-header welding, PWHT for alloy steel

·        Pre-aligned assembly reduces on-site work by 50-60% vs separate components

·        Suitable for 3.82MPa-25.4MPa boilers, all superheater stages

·        Delivery: 35-50 days, full documentation with material traceability

·        Expert support for hydraulic calculation and thermal expansion analysis

Technical Parameters

Applications

The Boyu Superheater Header & Coil Assembly is a complete convective superheater system integrating distribution headers with serpentine coils. Manufactured in Shandong, China under ASME S/U certification, this assembly provides a ready-to-install, pressure-tested superheater system. Certified with ISO9001, ASME S/U, Grade A, SGS and IBR, the product guarantees high quality and pressure boundary integrity.

This Superheater Header & Coil Assembly is widely used in power station boilers, industrial boilers, coking waste heat boilers, metallurgical exhaust gas boilers and large HRSG systems where complete superheater system fabrication is required. Its integrated design reduces on-site installation and ensures reliable performance across all superheater stages.