When a boiler boils over, prioritize safety and follow these steps: shut off the boiler’s power or fuel supply immediately, close all input valves to stop water flow, and allow the system to cool. Evacuate the area if there’s visible damage or danger, and contact a licensed technician for repairs. Do not attempt to restart the boiler until inspected.

Boiler boiling over typically occurs due to excessive pressure, faulty pressure relief valves, or water contamination. According to the Occupational Safety and Health Administration (OSHA), improper maintenance causes 15% of boiler-related workplace accidents annually, with explosions often resulting from unaddressed pressure issues. A 2021 study by the National Board of Boiler and Pressure Vessel Inspectors found that 30% of boiling over incidents involved valves not meeting ASME standards, highlighting the need for regular inspections. Property damage from boiling over can exceed $50,000 per incident, per data from the Insurance Institute for Property Loss Reduction (IPLR). Stopping the flow and cooling the system prevents further escalation, as rapid temperature changes can weaken metal components, increasing corrosion risks. OSHA recommends a 24-72 hour cooling period before reactivation. Proactive measures, such as annual pressure tests and valve replacements, reduce recurrence by 40%, as shown in a 2022 NFPA report. Ignoring these steps raises the likelihood of catastrophic failures, underscoring the importance of adhering to safety protocols.