Fluid Mechanics, HVAC & Refrigeration · Boiler horsepower
The most misleading unit in the plant room
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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 9.81 kW9.81\ \mathrm{kW} — which is more than THIRTEEN times the 746 W that the same word means on a motor nameplate. So Q=9.81BHPQ = 9.81\,\mathrm{BHP}, where QQ is the boiler's gross heat output in kilowatts and BHP\mathrm{BHP} 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: S=15.65BHPS = 15.65\,\mathrm{BHP}, with SS 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: B=SCOC1B = \dfrac{S}{\mathrm{COC} - 1}, with BB the continuous blowdown in kg/h and COC\mathrm{COC} 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. %CR=100ScS\%CR = \dfrac{100\,S_c}{S} is the condensate return percentage, where ScS_c is the condensate coming back in kg/h against SS the steam sent out. And what does not come back must be replaced: M=S(1%CR100)M = S\left(1 - \dfrac{\%CR}{100}\right), 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.