Boiler Steam Header

The core working principle of the boiler steam header (also known as steam manifold, steam distribution drum, steam distributor) is pressure-bearing expansion pressure stabilization and uniform steam distribution technology. As the core pressure-bearing special equipment in the steam boiler system, it takes the closed pressure-resistant cylinder as the carrier, eliminates the pressure fluctuation of the steam output from the boiler through the expansion buffer effect of the cylinder, stabilizes the system steam pressure, realizes the unified collection, pressure stabilization control, uniform distribution and multi-channel directional transmission of the steam produced by the boiler. At the same time, it realizes primary steam-water separation through reasonable internal flow channel design, and is equipped with reserved standardized interfaces for pressure gauge, thermometer, safety valve and sewage outlet to complete pressure monitoring, temperature monitoring, safety pressure relief and condensed water discharge of the steam system. It fundamentally ensures the stable steam supply of each steam consumption unit in the steam boiler system, and avoids equipment operation failures and energy waste caused by pressure fluctuation and uneven steam distribution. The design, production and testing of this equipment strictly comply with the mandatory specifications of Boiler Safety Technical Code TSG 11-2020 and Supervision Regulation on Safety Technology for Stationary Pressure Vessels TSG 21-2016 issued by the State Administration for Market Regulation of China, and also meet the relevant technical standards for pressure vessels formulated by the American Society of Mechanical Engineers (ASME). It is an indispensable core hub equipment in steam boiler heating systems and industrial steam pipe networks.

1. AIX Boiler: Factory Direct Strength and Core Brand Advantages

AIX Boiler is a professional factory direct manufacturer of boiler steam headers with national special equipment manufacturing qualification. It has an 18,000 ㎡ standardized pressure vessel production workshop, fully automatic CNC rolling and welding equipment, non-destructive testing laboratory and a professional R&D team for pressure vessel design, welding and testing. We have been deeply engaged in the field of boiler supporting pressure vessels for more than ten years, focusing on customizing highly adaptable steam header and steam manifold solutions for various steam boiler systems and industrial steam pipe networks. As an original factory direct supply enterprise, we eliminate all intermediate links. The core raw materials of all products are genuine steel from first-tier brands, supporting full-process non-standard customization. From nominal diameter, design pressure, number and layout of interfaces, to material selection, anti-corrosion treatment and supporting accessories, we can carry out exclusive design according to the user's boiler parameters, steam demand, on-site working conditions and industry specifications. It can be perfectly adapted to our full series of steam boiler equipment and water treatment systems. At the same time, we provide a full chain of services including design filing, production and manufacturing, testing and acceptance, installation guidance and after-sales operation and maintenance, and have provided stable and reliable steam header products and boiler system supporting services for more than 7000 industrial enterprises, chemical parks, hotels and hospitals, and municipal heating units nationwide.

We strictly abide by the quality control standards in the reference document. In the manufacturing process of steam headers and steam manifolds, we always adhere to the dual standards of advanced technology and strict quality control. Starting from the strict screening of raw materials, we ensure that every component is of high quality. The selected steel for boiler vessels has good strength and corrosion resistance, can withstand high temperature and high pressure working environment, and provides a solid foundation for the long-term stable operation of the equipment. In the processing and manufacturing link, we have introduced advanced CNC processing equipment and automated production lines to ensure the manufacturing accuracy of steam headers and steam manifolds. Each welding point is carefully processed, and the special welding process for pressure vessels is adopted to ensure firm welds and good sealing performance, effectively preventing steam leakage. At the same time, through a strict quality inspection system, each product is comprehensively tested to ensure that the product meets the relevant national standards and industry requirements.

Our product system covers the full series of steam header equipment. The core products include four core series: AIX boiler special standard steam header, non-standard customized steam manifold, high pressure steam distribution drum, and low pressure steam distributor, which can adapt to 0.5t/h-200t/h full tonnage steam boilers. Whether it is a small civil steam boiler, commercial heating boiler supporting steam header, or large industrial power plant boiler, chemical production steam pipe network, central heating steam system, we can provide a 100% matching pressure vessel solution to fully ensure the long-term safe, efficient and stable operation of the steam boiler system.

2. Core Product Series and Technical Parameters of AIX Boiler Steam Header

As a factory direct manufacturer with special equipment manufacturing qualification, we can provide customization services for all models and specifications of steam headers. The technical parameters of the core standard model products are shown in the table below. All parameters can be adjusted and optimized 1:1 according to the user's actual boiler supporting demand and on-site working conditions:

Note: The above are standard models. All products can be customized with non-standard specifications, materials, pressure ratings, interface quantity and layout according to user needs. We provide a full set of accessories including original pressure gauges, thermometers, safety valves, sewage valves, realizing one-stop procurement.

3. Core Structure and Functional Design of AIX Boiler Steam Header

AIX boiler steam header is specially optimized for high temperature resistance, high pressure resistance, impact resistance and long service life for steam boiler operation scenarios. It adopts standardized pressure vessel structure design. The core structure includes five core units: pressure-bearing cylinder, heads at both ends, standard flange interfaces, fixed support legs, function monitoring and safety accessories, which can be seamlessly connected with our steam boiler system and water treatment system. The core structure and functional design fully meet the technical requirements in the reference document, as follows:

1. Core Pressure-bearing Main Unit

The core pressure-bearing main body is composed of a cylinder and heads at both ends. The cylinder is integrally formed by CNC rolling with special steel plate for boiler vessels. The heads adopt standard elliptical heads, formed by CNC spinning, and adopt double-sided submerged arc welding process special for pressure vessels with the cylinder. The weld seam is formed evenly, no false welding or missing welding, and 100% non-destructive testing is carried out to ensure that the pressure-bearing performance meets the standard. It can withstand high temperature and high pressure steam working conditions for a long time, and is the core carrier for the steam header to realize pressure stabilization and distribution functions.

2. Standardized Flange Interface Unit

Multi-channel flange interfaces are customized according to the user's steam demand, including the main steam inlet and multi-channel branch steam outlets. The interface layout adopts symmetrical design to ensure the uniform distribution of steam in the cylinder, realize the uniform distribution of steam pressure and flow in each branch pipe, and avoid the problems of bias flow and pressure fluctuation. At the same time, standardized spare interfaces are reserved to facilitate the subsequent expansion of the user's steam consumption units and adapt to the steam demand of different scenarios.

3. Monitoring and Safety Accessories Interface Unit

Standardized functional interfaces are reserved on the cylinder, including pressure gauge reserved port, thermometer reserved port, safety valve interface, sewage discharge port, which fully matches the interface design requirements in the reference document: the pressure gauge interface is used to monitor the steam pressure in the cylinder in real time, the thermometer interface is used to monitor the steam temperature, the safety valve interface is used to install the safety pressure relief device, which automatically relieves pressure when the system pressure exceeds the set value to ensure system safety, and the sewage discharge port at the bottom is used to discharge condensed water in the cylinder to avoid water hammer and steam entrainment problems and ensure steam quality.

4. Fixed Support and Protection Unit

It adopts the combined design of saddle fixed legs and sliding legs, which adapts to the thermal expansion and cold contraction deformation of the cylinder, avoids structural stress caused by temperature changes during equipment operation. The height of the legs can be customized according to the on-site installation conditions. At the same time, it can be equipped with insulation layer and anti-corrosion layer according to user needs, adapting to various installation environments such as indoor, outdoor and open air, and extending the service life of the equipment.

5. Supporting Function of Steam System Pressure Stabilization

For the closed steam circulation system, it can be equipped with a stabilized pressure expansion unit to realize precise control of system pressure, which fully conforms to the system principle in the reference document: when the system pressure decreases, the pressure of the water chamber of the connected stabilizer decreases accordingly, the volume of the air chamber expands, and when the pressure drops to the set lower limit, the water pump is started by the controller to replenish water to the system, and the water pump stops running when the set pressure is reached; when the water in the system is heated and the volume expands, squeezing the air chamber, when the pressure rises to the upper limit, the water in the water chamber is discharged to the expander or softened water tank through the safety valve, the system pressure drops accordingly, and the pressure relief stops when the set value is reached, fully ensuring the stable pressure of the steam system.

4. Core Competitive Advantages of AIX Boiler Steam Header

• Factory Direct Supply, Complete Special Equipment Qualifications: We have our own pressure vessel production workshop and national special equipment manufacturing qualification, no intermediate price difference. All products are independently completed from design, production, testing to delivery. We can provide a complete set of filing materials including pressure vessel design drawings, quality certificates, non-destructive testing reports, etc., to meet the acceptance requirements of special equipment supervision departments in various regions, and fundamentally avoid compliance risks.

• Exclusive Non-standard Customization, Perfect Adaptation to Boiler Systems: 1:1 exclusive customization can be carried out according to the user's boiler model, steam parameters, number of steam consumption branches, and on-site installation space. The interface layout, pressure rating, and material selection are optimized for boiler operation scenarios, and can be perfectly adapted to our full series of steam boilers and water treatment equipment, realizing one-stop procurement, installation and commissioning of the whole boiler system, greatly reducing the user's procurement and communication costs.

• Advanced Seiko Technology, Strict Whole Process Quality Control: Strictly abide by the quality control standards in the reference document. The raw materials are selected from first-tier brands such as Baosteel and Ansteel for boiler vessel special steel plates, and each batch of raw materials has a material certificate and re-inspection report; welding adopts special CNC welding process for pressure vessels, operated by certified welders, and the welds are 100% non-destructive tested; each product has passed the hydraulic pressure test and air tightness test before leaving the factory to ensure that the product is delivered with zero defects, and the normal service life can reach more than 20 years.

• Scientific Structure Design, Ensuring Efficient and Stable Operation: Through reasonable cylinder diameter and internal flow channel design, uniform distribution of steam is realized, local accumulation of steam and pressure fluctuation are avoided, and each gas equipment can stably obtain the required steam volume; at the same time, it has good adjustment performance, which can flexibly adjust the steam distribution ratio according to the change of production load, improve energy utilization efficiency, reduce steam waste and enterprise operation cost; the equipment has low noise and small vibration during operation, which will not interfere with the surrounding environment and operators.

• Full Chain After-sales Service, Lifelong Operation and Maintenance Guarantee: We have a professional pressure vessel installation and after-sales operation and maintenance team, which can provide door-to-door delivery, installation guidance, filing assistance, and operation training services nationwide. After the equipment is delivered, we provide 12 months free warranty, lifelong supply of original factory parts, technical upgrade and regular inspection services, 7*24 hours technical response, to ensure the long-term stable operation of the user's equipment.

5. AIX Boiler Full Process Steam Header Solution Service System

As a professional factory direct manufacturer of boilers and pressure vessels, we not only provide high-quality steam header products, but also provide users with a full-process, one-stop supporting solution for steam systems, covering the whole project cycle:

1. Pre-design and Compliance Filing Services: We provide free on-site survey, parameter calculation, and drawing design services for users. Professional pressure vessel design engineers issue compliant steam header design drawings and a full set of filing materials according to boiler parameters, steam demand, and on-site working conditions to ensure that the products meet the requirements of special equipment supervision.

2. Original Factory Production and Whole Process Quality Control: All products are produced and processed in our own factory, and the whole process testing is carried out in strict accordance with the ISO9001 quality management system and pressure vessel manufacturing specifications. From raw material incoming inspection, welding process quality control, non-destructive testing, to factory hydraulic pressure test and air tightness test, each link has strict quality control to ensure that the products meet the design requirements and relevant national standards.

3. Logistics Distribution and On-site Installation Guidance: Professional logistics distribution system, door-to-door delivery nationwide, with professional technicians to provide on-site installation guidance, welding assistance, and system docking services to ensure standardized equipment installation and perfect docking with the boiler steam system.

4. Acceptance Filing and Operation Training: Provide users with a full set of product quality certification documents, test reports, and filing materials, and assist users in completing the acceptance and filing of special equipment; at the same time, provide one-to-one full-process training on equipment operation, daily maintenance, and safety management for user operators, and issue detailed equipment operation manuals, maintenance manuals and safety operation procedures to ensure that users can use the equipment in a standardized manner.

5. Lifelong After-sales and Operation Maintenance Guarantee: After the equipment is delivered, we provide free warranty service, lifelong supply of original factory parts, technical upgrading, regular inspection and on-site maintenance services, regularly return visit the equipment operation status, provide users with preventive maintenance suggestions, and fully solve the user's worries.

6. Relevant Industry Standards and Specifications for Boiler Steam Headers

The design, production, testing and acceptance of all AIX boiler steam header products are strictly in accordance with the current relevant national standards and specifications. The core implementation standards include:

• Pressure Vessels GB 150.1~150.4-2011

• Boiler Safety Technical Code TSG 11-2020

• Supervision Regulation on Safety Technology for Stationary Pressure Vessels TSG 21-2016

• Welding Procedure Qualification for Pressure Equipment NB/T 47014-2011

• Non-destructive Testing of Pressure Equipment NB/T 47013-2015

• Code for Construction of Field Equipment and Industrial Pipeline Welding Engineering GB 50236-2011

Our products have fully passed the testing of third-party authoritative institutions. The pressure-bearing performance, welding quality and safety performance fully meet the relevant national standards and special equipment supervision requirements, which can meet the needs of annual inspection, special equipment acceptance and compliant use of various steam boiler systems, and also adapt to the scene use requirements of chemical, food, pharmaceutical, heating and other industries.