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Headers & Pots

Instrumentation Hardware

Instrument air headers and condensate / seal pots fabricated from 1" to 4" seamless or ERW pipe, Sch 40 to Sch XXS — in SS 304, SS 316, SS 316L, Carbon Steel and nickel alloys, built to your inlet, outlet and drain layout.

Stainless steel instrument air header and condensate pot
20 kg/cm² TestedStandard test pressure*
Product Overview

Air Headers & Condensate / Seal Pots

Instrumentation hardware covers the fabricated pieces that sit between the process and the instrument. An air header takes plant instrument air from one inlet and distributes it to many control valves, positioners and pneumatic instruments through individual outlet valves. A condensate or seal pot sits in the impulse line of steam and vapour flow measurement, holding a stable liquid column so the transmitter sees a true differential pressure.

Kalpataru builds both from 1" to 4" seamless or ERW pipe in Sch 40 to Sch XXS, with the inlet, outlet and drain connections machined and welded to your layout. Every assembly is pressure tested before dispatch.

  • 1" to 4" header / pot sizes
  • Seamless or ERW pipe
  • Flanged or valved inlet
  • Needle / ball valve outlets
  • 3 way & 4 way seal pots
  • Pressure tested assemblies
Request a Quote View Dimensions
Pipe Size1" to 4" Seamless / ERW
ScheduleSch 40, 80, 160, XXS, C Class
End ConnectionsFlange, NPT / BSP, Valved
MaterialsSS 304 / 316 / 316L, CS, Alloys
01
Types

Instrumentation Hardware Types

AH
Air header (air manifold) with ball valve outlets

Air Headers (Air Manifolds)

A header pipe with a single inlet and a row of outlet take-offs to distribute compressed air to instruments.

  • TypeMultiway outlets (as per specification)
  • End Conn.TOD / FPT / MPT
  • Tube OD1/4" to 1" OD (Fractional)
    6 mm to 25 mm OD (Metric)
  • Thread1/8" to 2" NPT (Taper); BSPP / BSPT / ISO / Metric on request
  • MOCCS galvanized with CS / SS or brass valves, or complete SS with SS valves (SS 304 / SS 316)
  • Header Pipe1" to 4" (seamless or ERW); Sch. 40 / 80 / 160 / C class
  • InletRF / FF flange (ANSI B16.5) 1/2" to 3", ball valve 1/4" to 2", flange & valve, or valve & three piece union
  • Outlet / DrainNeedle valves, ball valves (CS / Brass / SS 304 / SS 316) or pipe male / female open threads
  • Test PressureStandard 20 kg/cm² (high pressure test can be offered)
  • Outlet PatternParallel or zig-zag. Outlet spacing and nipple length to be specified
CP
Condensate / seal pot

Condensate / Sealpot

A pipe chamber closed with end caps and fitted with threaded ports. It collects condensate in steam and vapour impulse lines, or holds seal fluid to isolate the transmitter from corrosive or viscous process media.

  • End Conn.FPT / SW
  • Pipe Size1.5" to 4", Sch. 40 to Sch. XXS
  • Type3 Way / 4 Way. IBR certificate optional
  • Thread (FPT)1/4" to 2" NPT (up to 9000 psi); BSPP / BSPT / ISO / Metric on request
  • Socket Weld1/4" to 2" NB (up to 9000 psi)
  • Drain PlugsHex plugs provided optionally. Length of pipe / pipe schedule to be specified
  • MOCSS 316, 304 / Alloy 400, 600, C276 / CS
QRC
Quick release coupling

Quick Release Coupling

Push-to-connect coupling for fast, tool-free connection and disconnection of instrument and test lines.

  • End Conn.TOD / FPT / MPT
  • Tube OD1/4" to 1" OD (Fractional)
    6 mm to 25 mm OD (Metric)
  • Thread1/8" to 1" NPT (Taper); BSPP / BSPT / ISO / Metric on request
  • TypeSingle Check Type / Double Check Type
  • MOCSS 316, 304 / Brass / Alloy 400, 600, C276 / CS
  • Model No.MOC*-QRC-IN*-OUT*
02
Specifications

Technical Specifications

Air Headers

ProductInstrument Air Header / Air Distribution Header
Header Pipe Size1", 1-1/4", 1-1/2", 2", 2-1/2", 3", 4" — Seamless or ERW pipe
Pipe ScheduleSch 40, Sch 80, Sch 160, C Class (heavy)
Inlet ConnectionFlange to ANSI / ASME B16.5, 1/2" to 3"; or ball valve 1/4" to 2"; or flange and valve both at inlet
Outlet ConnectionNeedle valves, ball valves, or male / female open pipe threads (NPT / BSP)
Drain ConnectionNeedle valve, ball valve or threaded plug at the header end
Number of OutletsAs per customer layout — single row or double row take-offs
Test PressureStandard 20 kg/cm² (approx. 284 PSI); higher pressure testing offered on request
MaterialsSS 304, SS 316, SS 316L, Carbon Steel & others on request
CertificatesEN 10204 3.1 material certificate, pressure test certificate, third party inspection on request

Condensate / Seal Pots

ProductCondensate Pot / Seal Pot / Condensate Chamber
Pot Pipe Size1" to 4" — Seamless or ERW pipe
Pipe ScheduleSch 40 to Sch XXS
Type3 way / 4 way
End ConnectionsPipe thread 1/4" to 2" NPT / BSP & others
Pressure RatingUp to 9000 PSI, depending on pipe size, schedule and material
ConstructionPipe body with end caps; threaded half couplings or bosses for process, instrument, vent and drain ports
MaterialsSS 304, SS 316, SS 316L, Carbon Steel, Brass, Inconel, Monel, Hastelloy C & others
TestingHydrostatic test, dimensional inspection, PMI on request
CertificatesEN 10204 3.1 material certificate, test certificate, third party inspection on request
03
Materials

Material Grades

Stainless Steel

SS 304 SS 316 SS 316L

Carbon Steel

CS ASTM A106 Gr. B CS ASTM A53 Gr. B (ERW) CS IS 1239 C Class

Nickel & Copper Alloys (Condensate / Seal Pots)

Monel 400 Inconel 600 Hastelloy C-276 Brass
MaterialUNS No.Seamless PipeWelded / ERW PipeFlanges / Bosses
SS 304S30400ASTM A312 TP304ASTM A312 TP304 (welded)ASTM A182 F304
SS 316S31600ASTM A312 TP316ASTM A312 TP316 (welded)ASTM A182 F316
SS 316LS31603ASTM A312 TP316LASTM A312 TP316L (welded)ASTM A182 F316L
Carbon SteelK03006ASTM A106 Gr. BASTM A53 Gr. B / IS 1239ASTM A105
Monel 400N04400ASTM B165—ASTM B564
Inconel 600N06600ASTM B167—ASTM B564
Hastelloy C-276N10276ASTM B622ASTM B619ASTM B564
04
Material Charts

Chemical & Mechanical Properties

GradeCMnSiPSCrNiMoOthers
SS 3040.082.001.000.0450.03018.0–20.08.0–10.5—N 0.10
SS 3160.082.001.000.0450.03016.0–18.010.0–14.02.0–3.0N 0.10
SS 316L0.0302.001.000.0450.03016.0–18.010.0–14.02.0–3.0N 0.10
CS A106 Gr. B0.300.29–1.060.10 min0.0350.0350.400.400.15Cu 0.40, V 0.08
Values in weight %. Single values are maximum unless stated. Limits as per the applicable ASTM specification.
GradeTensile Strength (MPa, min)Yield Strength 0.2% (MPa, min)Elongation (%, min)Hardness (max)
SS 30451520540201 HB
SS 31651520540217 HB
SS 316L48517040217 HB
CS A106 Gr. B41524030*—
Stainless steel values in annealed condition. *Carbon steel elongation is the basic longitudinal value; actual minimum depends on wall thickness.
GradeDensity (g/cm³)Melting Range (°C)Key Characteristic
SS 3048.001400–1450General corrosion resistance, economical
SS 316 / 316L8.001375–1400Molybdenum for chloride & pitting resistance
CS A106 Gr. B7.851425–1540High temperature service, economical for dry air & steam
05
Dimensions

Dimension & Sizing Tables

Pipe Wall Thickness — 1" to 4" (ASME B36.10)

Nominal SizeOD (mm)Sch 40 (mm)Sch 80 (mm)Sch 160 (mm)XXS (mm)
1"33.43.384.556.359.09
1-1/4"42.23.564.856.359.70
1-1/2"48.33.685.087.1410.15
2"60.33.915.548.7411.07
2-1/2"73.05.167.019.5314.02
3"88.95.497.6211.1315.24
4"114.36.028.5613.4917.12

Air Header — Typical Outlet Options

Header SizeTypical OutletsOutlet SizeTypical InletOutlet Fitting
1"4 – 61/4", 3/8", 1/2" NPT / BSP1/2" – 1" flange or ball valveNeedle / ball valve or open thread
1-1/2"6 – 101/4", 3/8", 1/2" NPT / BSP1" – 1-1/2" flange or ball valveNeedle / ball valve or open thread
2"8 – 121/4", 3/8", 1/2" NPT / BSP1" – 2" flange or ball valveNeedle / ball valve or open thread
3"10 – 161/4" – 3/4" NPT / BSP2" – 3" flangeBall valve or open thread
4"12 – 201/4" – 1" NPT / BSP3" flangeBall valve or open thread

Condensate / Seal Pot — Volume Guidance (Sch 80)

Pot SizeID (mm)Volume per 100 mm (cm³)Typical Body Length (mm)Approx. Volume (L)Typical Use
1"24.3462000.09Low volume DP transmitters
1-1/2"38.11142500.29Small steam flow elements
2"49.21902500.48General steam & vapour DP flow
3"73.74262501.07Large impulse volumes, seal fluid reserve
4"97.27423002.23Seal pots with large fluid reserve
All dimensions and volumes are typical values for reference only. Outlet counts, lengths and port positions are built to your layout, and final dimensions are confirmed on the approved drawing for your order.
06
Applications

Where Our Headers & Pots Are Used

Instrument Air Distribution

Control Valve & Positioner Supply

Steam Flow DP Measurement

Power Plant Boilers

Refineries & Petrochemicals

Chemical Seal Fluid Systems

Fertiliser & Gas Plants

Skid & Package Units

07
Why Kalpataru

Features & Advantages

Built to Your Layout

Header length, outlet count, pitch, sizes and valve types follow your hook-up drawing — no forcing a standard part to fit.

Pressure Tested

Every header is tested at 20 kg/cm² as standard, and pots are hydro tested to suit the rating; higher test pressures on request.

Single Source Assembly

Header or pot, outlet needle / ball valves and fittings are supplied as one tested assembly from one manufacturer.

Full Traceability

Pipe heat numbers recorded against mill certificates, with 3.1 certificates supplied with every order.

08
FAQ

Frequently Asked Questions

What is the difference between a condensate pot and a seal pot?
The hardware is similar; the job differs. A condensate pot is used on steam and condensable vapour lines, where it lets vapour condense and keeps equal liquid heads on both impulse legs of a DP transmitter. A seal pot is filled with a compatible seal fluid that separates the transmitter from corrosive, viscous or hot process media.
What information do you need to quote an air header?
Header pipe size and schedule, material, overall length, inlet type and size (flange rating, ball valve or both), number, size and spacing of outlets, outlet valve type (needle or ball) or open thread, drain arrangement and test pressure. A sketch or hook-up drawing is the quickest way to share this.
What is the difference between 3 way and 4 way condensate pots?
A 3 way pot has process, instrument and drain / vent connections. A 4 way pot adds a further port, typically a separate vent or fill connection, so the pot can be filled with seal fluid or vented without disturbing the instrument line.
Which material should I choose for an instrument air header?
SS 304 suits most dry instrument air in indoor or mild environments. SS 316 / 316L is preferred in coastal, offshore and chemical plants where chlorides are present. Carbon steel headers are an economical option for dry, filtered air in non-corrosive areas.
09
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Need an Air Header or Condensate Pot Built?

Send your layout sketch or data sheet — we will quote with material certificates, test pressure and delivery schedule.

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