All Topics
Emergency Situations
How to respond to low water, overpressure, flame failure, and other emergencies.
Low Water Emergency
A low-water condition is the most dangerous boiler emergency. It can lead to overheating, tube failure, and explosion.
- 1. SECURE THE BURNER immediately — this is ALWAYS the first action
- 2. Verify actual water level using try cocks
- 3. Do NOT add water if the boiler may be overheated
- 4. Let the boiler cool naturally
- 5. Notify supervision and document
- 6. Investigate root cause before restarting
- 7. Boiler must be inspected before returning to service
NEVER add water to an overheated boiler. Cold water on hot metal causes explosive steam generation.
Overpressure / Safety Valve Lifting
If pressure exceeds the set point and the safety valve lifts, the system is working as designed. If the valve does NOT lift, there is a serious problem.
- Reduce firing rate immediately
- If pressure continues rising, secure the burner
- NEVER gag, block, or restrict a lifting safety valve
- If safety valve fails to lift at set pressure, shut down and report
- Check pressuretrol operation — it should have shut off the burner before the safety valve lifted
Flame Failure
When the flame goes out during operation, the flame safeguard system should automatically shut off the fuel.
- Verify fuel supply is secured
- PURGE the furnace before any restart attempt
- Investigate root cause: fuel supply, ignition, flame scanner, air/fuel ratio
- Do NOT repeatedly reset without investigating
- Never bypass flame safeguards to restart
Furnace Explosion
A furnace explosion occurs when accumulated combustible gases ignite inside the furnace. It is caused by improper purging or failed safety controls.
- Prevention: proper pre-purge before every start
- Prevention: functioning flame safeguard system
- Prevention: never bypass safety interlocks
- If a furnace explosion occurs: secure all fuel, evacuate the area, notify emergency services
- Do NOT restart without thorough inspection