Hi,
>> Also, we can see that 9.2.3 has been released now and has a number of fixes relating to WAL replay, so we have decided to try again using that.
>> We will scrub the standby and make a fresh copy using pg_basebackup. If that doesn't work then we may try using rsync instead.
I am pleased to be able to report that the problem seems to be fixed after upgrading to 9.2.3.
We upgraded the standby server only to 9.2.3, rebuilt the standby using pg_basebackup, and then started it up. It replayed all the outstanding WAL files with no problems.
Regards // Mike