If your water heater thermocouple keeps failing or blowing out repeatedly, it is typically caused by drafts in the utility room extinguishing the pilot flame, inadequate combustion air supply, a misaligned pilot burner bracket, or a failing gas control valve that cannot sustain the millivolt signal. Additionally, heavy soot buildup from incomplete gas combustion can coat the thermocouple tip, insulating it from the flame and causing it to drop below the required operating millivolt threshold. Verification: Inspect the utility room for excessive drafts and verify a clean, steady blue pilot flame.
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