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Boiler Blowdown Rate & Makeup Water Capacity Calculator

Determine water treatment blowdown flow and total feedwater pumping capacity to maintain boiler chemistry standards.

System Presets:

Boiler & Operating Parameters

Design inputs for steam output, pressures & line drops
PSI
%
%
Discharge Piping & Pressure Drops
ft
Deaerator Suction & NPSH Parameters
ft
ft
ft
%
%

Pump Sizing Output & Hydraulic Head

Real-time ASME dynamic calculations & cavitation analysis
Feed Pump Flow Rate
26.2
GPM (99.2 L/min)
Total Dynamic Head (TDH)
514
Feet of Liquid (213 PSI)
Shaft Brake Horsepower
5.0
BHP (3.7 kW Hydraulic)
Recommended Motor
7.5 HP
NEMA Frame (5.5 kW IEC)
NPSH Cavitation Margin (NPSHA - NPSHR) Safe Margin
NPSHA is 16.5 ft vs NPSHR of 8.0 ft (Margin: +8.5 ft / 2.06x ratio). Suction static elevation is safe from boiling cavitation.
System Flow Schematic (P&ID) Live Hydraulics
Hydraulic Component Pressure (PSI) Head (Feet)
Boiler Design Safety Pressure (+3%) 154.5 PSI 372.9 ft
Feedwater Control Valve Drop 20.0 PSI 48.3 ft
Economizer Heat Recovery Coils 15.0 PSI 36.2 ft
Discharge Piping & Check Valve Loss 10.0 PSI 24.1 ft
Static Elevation Lift 6.2 PSI 15.0 ft
Total Feed Pump Discharge Target 205.7 PSI 514.0 ft

Cycle of Concentration and Blowdown Mass Balance

As steam boils off pure H2O vapor, dissolved minerals and solids remain inside the boiler drum, concentrating over time. Without continuous surface blowdown, high TDS leads to foaming, boiler priming, wet steam carryover, and scale deposition on heat transfer tubes. The percentage of blowdown required is: Blowdown % = (Feedwater TDS / (Boiler Water Max TDS - Feedwater TDS)) x 100%. If feedwater has 150 ppm TDS and boiler limit is 3,000 ppm, blowdown is approximately 5.26%. Feedwater pump sizing must account for this extra mass flow over pure steam production.

Master Boiler Feedwater Equations:
1. Base Evaporation: Mass_steam (lb/hr) = BHP x 34.5
2. Feed Mass Flow: Mass_feed (lb/hr) = Mass_steam / (1 - Blowdown_fraction) x Safety_Factor
3. Volumetric Flow: GPM = Mass_feed / (500 x Specific_Gravity)
4. Total Dynamic Head: TDH (ft) = [P_discharge (PSI) - P_suction (PSI)] x 2.31 / Specific_Gravity
5. Deaerator NPSHA: NPSHA (ft) = H_static (elevation above pump) - H_suction_friction (ft)
6. Pump Shaft Power: BHP_pump = (GPM x TDH x Specific_Gravity) / (3,960 x Pump_Efficiency)
ASME Section I Code Guidelines
Boilers with more than 500 sq ft of heating surface require at least two independent means of feeding water. Each feed source must supply sufficient water to maintain safe operating levels when firing at full burner capacity.
Deaerator Elevation Standards
Because water in the deaerator vessel is at saturated steam conditions, the storage tank must be physically elevated on structural steel to provide sufficient static liquid column (typically 12 to 24 feet) to prevent pump cavitation.
Minimum Flow Recirculation
Multistage centrifugal feed pumps generate rapid internal friction heat at low flow. An automatic minimum-flow bypass line back to the deaerator prevents liquid flashing and destructive thermal seizure when modulating valves throttle back.

Boiler Feedwater Calculators & Engineering Tools

Explore specialized calculators for flow rate conversion, TDH summation, deaerator sizing, and motor specifications.

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