The most misleading unit in the plant room
A boiler horsepower is not a horsepower. It is a POWER — 33,475 BTU per hour, or — which is more than THIRTEEN times the 746 W that the same word means on a motor nameplate. So , where is the boiler's gross heat output in kilowatts and is the bare nameplate rating. A 200 bhp boiler is a 1,962 kW appliance, not a 149 kW one, and reading the two units as the same thing has under-sized real gas trains and real flues.
The same rating also reads as a steam rate: , with the steam production in kg/h. The definition was written in 1889 as 34.5 lb/h from and at 212 °F, and 34.5 lb is 15.65 kg. That qualifier matters: real feedwater arrives far below boiling, so a boiler making its nameplate steam is working harder than the definition admits.
Steam leaves its dissolved solids behind in the drum, exactly as evaporation does in a cooling tower, so the same algebra returns: , with the continuous blowdown in kg/h and the cycles the drum chemistry allows. Boilers run at far higher cycles than towers — often 20 or more — because their makeup is softened or demineralised before it ever reaches the drum.
Two more lines close the plant's water balance. is the condensate return percentage, where is the condensate coming back in kg/h against the steam sent out. And what does not come back must be replaced: , the makeup in kg/h. Returned condensate is hot, already treated and nearly free; makeup is cold, must be softened, and brings oxygen with it. Condensate return percentage is the single headline number of any steam plant, and every point of it is money.