Why is it important to maintain proper water levels in a boiler?

Maintaining proper water levels in a boiler is crucial primarily to prevent overheating and potential boiler failure. When the water level is too low, there is insufficient coolant to absorb the heat generated by the combustion process, which can lead to the overheating of boiler components. This overheating can cause various severe issues, such as thermal stress, metal fatigue, and even catastrophic failure of the boiler itself. Such failures might result in serious safety hazards, including explosions or leaks of hazardous materials, endangering both personnel and equipment.

Proper water levels also play a role in overall system efficiency and safety. While other factors like steam quality or fuel efficiency can be affected by water levels indirectly, the immediate and most critical reason to maintain correct levels is to protect the boiler from harmful operating conditions.