Water-tube boilers operate at the highest pressures and temperatures in industrial steam generation, making their spare parts critical for plant reliability and safety. AQ Process Systems sources and exports the full range of water-tube boiler spares, from individual replacement tubes to complete tube panels, headers, and drum internal assemblies.
We source waterwall tubes, superheater tubes, and economizer tubes in carbon steel, low-alloy (T11, T22, T91), and stainless steel grades with full Mill Test Certificates. Headers, downcomers, and nozzle forgings are available machined to OEM specifications.
For planned outage support, we can supply complete spare part packages covering tubes, gaskets, refractory, soot blower elements, and safety valves, consolidated into a single shipment to minimise procurement complexity.
| Component | Specification | Description |
|---|---|---|
| Tubes & Panels | ||
| Waterwall Tubes | SA 178, SA 210, SA 213 T11/T22/T91 | OD 38 to 76mm | Membrane wall and tangent tube replacements, supplied straight or pre-bent to OEM profiles. |
| Superheater Tubes | SA 213 T11/T22/T91/TP304H/TP347H | High-temperature alloy | Primary and secondary superheater coils in alloy and stainless grades for creep resistance. |
| Economizer Tubes | SA 210 Gr. A1/C | Bare or finned | Bare tube and finned tube economizer replacements, solid, serrated, or helical fin options. |
| Membrane Wall Panels | Pre-fabricated welded panels | CS or alloy | Complete membrane wall panel sections, tubes welded to flat bar, ready for field installation. |
| Headers & Drums | ||
| Headers & Manifolds | SA 106 Gr. B/C, SA 335 P11/P22 | Drilled & machined | Replacement headers for waterwall, superheater, and economizer circuits, drilled to OEM stub pattern. |
| Downcomers & Risers | SA 106 Gr. B/C | Large bore | Pre-bent | Downcomers, risers, and connecting tubes between steam drum and waterwall circuits. |
| Steam Drum Internals | Cyclone separators, chevron demisters, baffles | Complete drum internal kits, cyclone separators, chevron demisters, feedwater distribution pipes. |
| Mud Drum Internals | Baffles, blowdown connections, access fittings | Lower drum internals including baffles, sludge collectors, and continuous blowdown fittings. |
| Structural & Support | ||
| Buckstays & Tie Bars | Structural steel | Welded or bolted | Boiler casing support structures that resist internal pressure on flat membrane wall surfaces. |
| Tube Hangers & Supports | Alloy steel | Various configurations | Pendant and horizontal tube support hangers, alloy steel for high-temperature zones. |
| Expansion Joints | Metallic bellows or fabric | Single or multi-ply | Duct and casing expansion joints accommodating thermal growth, metallic or fabric type. |
| Windbox Components | CS fabrication | Dampers, seals, air nozzles | Windbox structural parts, air distribution nozzles, and secondary air damper assemblies. |
| Soot Blowing & Cleaning | ||
| Soot Blower Elements | Long retractable or wall-mounted | SS lance tubes | Replacement lance tubes, nozzles, and feed tubes for retractable and rotary soot blowers. |
| Soot Blower Drive Units | Gear motors, limit switches, couplings | Motor drives, gearboxes, travel limit switches, and packing glands for soot blower mechanisms. |
| Safety & Instrumentation | ||
| Safety Valves | ASME Sec I Code-stamped | Flanged | Drum and superheater safety valves, spring-loaded, ASME-stamped, with test gag and lifting lever. |
| Drum Level Transmitters | DP type or guided wave radar | 4-20mA/HART | Three-element drum level measurement, differential pressure or radar type with HART protocol. |
| Pressure & Temperature Instruments | Transmitters, gauges, thermowells | Steam drum pressure, superheater outlet temperature, and flue gas temperature instrumentation. |
| Refractory & Insulation | ||
| Castable Refractory | Low-cement, high-alumina | 1600°C+ rated | Combustion zone refractory for burner throats, windbox openings, and observation ports. |
| Insulation & Cladding | Mineral wool, calcium silicate | Aluminium cladding | External insulation materials and weather-protective aluminium or stainless cladding. |
Parts are matched to OEM material specifications and dimensional tolerances. Please provide the equipment manufacturer, model number, and serial number (if available) for precise part identification. Mill Test Certificates (MTC) supplied with all tube materials per EN 10204 3.1.
The most frequently required water-tube boiler spares include waterwall tubes (due to erosion, corrosion, or overheating), superheater tubes (creep damage at high temperatures), economizer tubes (acid dew point corrosion), soot blower elements (lance tube erosion), drum internals (cyclone separators and demisters), safety valves, and expansion joints.
Water-tube boilers use carbon steel tubes (SA 178, SA 210) for waterwalls and economizers operating below 450°C, low-alloy tubes (SA 213 T11, T22, T91) for superheaters operating at 450 to 600°C, and stainless steel tubes (TP304H, TP347H) for the highest-temperature sections. AQ Process Systems sources and exports all grades with Mill Test Certificates.
Yes. We supply complete membrane wall panel sections with tubes welded to flat bar (membrane bar), pre-bent to OEM profiles, and ready for field installation. Panels can be fabricated in carbon steel or alloy grades to match the original boiler design.
Yes. We supply OEM-compatible parts for all major water-tube boiler manufacturers including Babcock & Wilcox, Thermax, Doosan, IHI, BHEL, Mitsubishi Power, and Valmet. Parts meet original material specifications and dimensional tolerances.
A typical outage package includes replacement tubes (waterwall, superheater, economizer), gaskets, soot blower lance tubes and nozzles, refractory materials, safety valves for recertification, drum level gauge glasses, and instrumentation consumables. We consolidate everything into a single shipment.
Yes. For critical breakdowns, we offer expedited sourcing and shipping. Common tube grades and sizes can often be dispatched within 48 to 72 hours from our supply network. Contact us with the boiler make, model, and failed component details for fastest response.
Share your equipment make, model, and part numbers, we respond within 24 hours.