Hood1,
From the description, it looks like you are looking at using a pair of trunnions coming horizontally off the sides of the riser for support. For that kind of application in a line that big, I'd consider using a lug type of arrangement that you see used on vertical exchangers. With that orientation, the main load will be the longitudinal bending in the header and I think it would be easier/cheaper to size the gusset plates to be as long as you need to get a good section modulus and distribute the load.
And, I'd highly recommend consulting with an engineering company and get a pipe stress or vessel engineer to do this for you. The nature of your questions suggests that this kind of design work is not your normal function. Edward L. Klein
Pipe Stress Engineer
Houston, Texas
All opinions expressed here are my own and not my company's.