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Nuisance Pilot Flame Failure on Fulton Boilers

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Posted by Mark Ayotte on September 16, 2008 at 15:34:05:

Our Facility is 2 years old. We have 2 Fulton High Pressure boilers Model ICS-60 {60 HP}. Both boilers have had a history of tripping out on pilot flame failure {Fault # 28 on relay module}. The electrodes have been replaced and gap set, Flame detector sighting is good, flame signal 5.0 Vdc, spark is good, new pilot solenoid valve and pilot regulator, new flame amplifier. The boiler calls for 14" W.C. incoming gas pressure. We have by design 2 lbs {56" W.C.}. The pilot Reg was replaced with a 5 PSI Reg. as well as the main gas Reg.The local gas company installed a recorder and it verifies a relatively steady gas pressure 56-70" W.C.
We also have (2) 500 HP low pressure Cleaver Brooks boilers. The low pressure boilers are never a problem. Only one HP boiler runs at a time from 7 AM until 3 PM.
My questions are 1.Can the starting and stopping of the LP boilers cause a pressure drop or surge which could affect the HP boilers if they were in a trial for ignition at the same time? 2. Can the high gas pressure cause the pilot gas to blow by the spark and not light causing ignition failure?
The HP boilers can run a whole week and not trip and then trip several times a day.

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