Furnace Problems

You should not operate this furnace outside of the manufacturers required specifications. Certainly, a working flame sensor is an absolute requirement. You risk an explosion, a fire, or at the very least, a compromise of air quality.

The unit should be repaired to 100% working order, or replaced. Anything short of that is putting in risk property, and/or lives.

"We have a poor flame sensing circuitry in our plant.They are IR based sensors which never worked properly."

Your equipment should be brought up to date immediately.

http://hpsweb.honeywell.com/Cultures/en-US/Products/Instrumentation/tempsensors/noncontact/default.htm

Honeywell offers a line of IR sensors that are affordable and very dependable.

rajeshmadapati,

The detector circuitry must be replaced. You need IR as well as UV detection. The detectors must be "aimed" properly. IR detectors can get a reading off of hot refractory and allow the fuel to keep dumping into a hot firebox and this is a real invitation for disaster. Several years ago I saw the result of a firebox explosion that caused $300K US in damage. The explosion was caused by 6 gallons or so of #2FO that hit the hot refractory because of a faulty and/or obsolete flame detector. The external walls of the firebox bowed out 17 inches. We were lucky that this firebox had the outer walls "re skinned" recently with a much higher gauge steel. It was nothing short of a miracle that no one got injured or worse and that the plant is still standing. Seeing the aftermath of an event like this once in a lifetime is enough for me. You should replace the system now. Ed