Infrared thermography plays a crucial role in enhancing safety, efficiency, and asset integrity within the petrochemical and refining sectors. At PROtect, Jason Czajkowski, IRT Thermography Manager, is pioneering the use of advanced technologies for furnace inspections.
As a certified Master Thermographer and CWI, Czajkowski and his team have become early adopters of FLIR's latest inspection tool, the FLIR G609. This transition from the previously utilized GF309 to the more sophisticated G609 marks a significant advancement in high-heat industrial inspections.
Resolution Improvement with the FLIR G609
The FLIR GF309, a long-standing choice for infrared furnace checks, offered a resolve of 320 × 240 pixels
The FLIR GF309, a long-standing choice for infrared furnace inspections, offered a resolution of 320 × 240 pixels. However, this posed challenges in detecting subtle temperature anomalies from a distance.
The newly implemented FLIR G609 boasts a resolution of 640 × 480 pixels, significantly enhancing the ability to pinpoint early indicators of issues such as coke buildup or flame impingement. In industries where early problem identification can prevent catastrophic failures, the enhanced resolution of the G609 is pivotal.
Advanced G-Series Features
The sophistication of the G609 extends beyond resolution. The device includes a redesigned heat shield secured with a single screw, providing superior protection for inspectors during live furnace operations. Its user-friendly 4-inch touchscreen interface allows quick navigation, even when wearing gloves.
The 1-Touch Level/Span feature further streamlines the process by automatically adjusting image contrast, enabling inspectors to focus on data collection rather than manual settings.
Additionally, the G609's specially calibrated furnace lens effectively captures thermal images through flames and refractory, a challenge for previous systems. As Czajkowski points out, "It’s not just about seeing through the flame it’s about seeing what matters behind it."
Comprehensive Software Integration
G609 guides inspectors through these pre-defined routes, reducing the risk of missing essential components
Coupling the G609 with FLIR's Thermal Studio Pro software transforms it into a robust inspection and reporting tool. The Route Creator plug-in allows PROtect to plan inspections in advance, optimizing routes and ensuring thorough inspections.
Once on site, the G609 guides inspectors through these pre-defined routes, reducing the risk of missing essential components. Thermal Studio Pro also expedites post-inspection reporting by batch processing images and applying uniform templates, sharply reducing the time needed for report generation.
Czajkowski notes, "The software enables consistency and speed. We can now deliver high-quality reports faster than ever before."
Investment in Durability and Usability
The decision to adopt the G609 represents a long-term investment in reliability and performance. Its robust construction and compatibility with evolving software platforms make it a valuable tool for onboarding new personnel without compromising inspection quality.
Real-world applications at PROtect have already demonstrated its effectiveness in identifying potential issues that older models may have overlooked.
The introduction of the FLIR G609 is transforming IR furnace inspections. Guided by Jason Czajkowski's expertise at PROtect, this technology offers exceptional image clarity, intuitive controls, and seamless software compatibility. As the petrochemical and refining industries continue to raise the bar for safety and operational uptime, PROtect's adoption of the G609 ensures it remains at the forefront of industry standards.
Infrared thermography has become an indispensable tool in the petrochemical and refining industries, and Jason Czajkowski, IRT Thermography Manager at PROtect, is leading the charge in applying the latest technologies to improve safety, efficiency, and asset integrity.
A Level III #13966 certified Master Thermographer and CWI, Czajkowski and his team at PROtect are early adopters of FLIR’s newest furnace inspection tool: the FLIR G609. This article outlines why PROtect transitioned from the trusted GF309 to the advanced G609 and how this upgrade is transforming furnace inspections in high-heat industrial environments.
Why upgrade? The resolution advantage
For years, the FLIR GF309 was the standard for IR furnace inspections, but it offered only 320 × 240 pixel resolution. Czajkowski recognized the limitations this presented specifically, lower image clarity and reduced ability to spot subtle temperature anomalies at a distance.
The FLIR G609, with its 640 × 480 resolution, delivers over four times the pixel count, enabling inspectors to identify small, early-stage issues such as coke buildup or flame impingement that may have gone unnoticed with older technology.
In an industry where early detection can mean the difference between a planned repair and a catastrophic failure, resolution matters.
Smarter technology in the G-Series
Beyond improved resolution, the G609 brings a suite of advanced features that modernize the inspection process. Its redesigned heat shield mounts with a single screw and provides superior protection during live furnace inspections. The intuitive 4-inch touchscreen interface allows for quick navigation, even with gloved hands.
Czajkowski emphasizes the value of the 1-Touch Level/Span feature, which automatically adjusts image contrast with a single tap. This allows inspectors to focus on capturing actionable data instead of fumbling with manual settings.
Additionally, the G609’s custom furnace lens is calibrated to capture clear thermal images through furnace flames and refractory, something legacy systems struggled with. According to Czajkowski, "It’s not just about seeing through the flame it’s about seeing what matters behind it."
The software advantage: A total inspection solution
Pairing the G609 with FLIR’s Thermal Studio Pro software transforms the camera into a full inspection and reporting solution. PROtect leverages the Route Creator plug-in to plan inspections in advance, assigning inspection points and optimal paths. Once on site, the G609 guides inspectors through this pre-planned route, ensuring no critical component is missed.
Thermal Studio Pro streamlines post-inspection reporting by batch processing images and applying consistent templates. Reports that once took hours to compile can now be generated in minutes, improving turnaround times for clients. "The software enables consistency and speed," says Czajkowski. "We can now deliver high-quality reports faster than ever before."
Future-proofing and field learnings
Czajkowski notes that the G609 isn’t just an improvement in specs it represents a long-term investment in reliability. Its durable design, compatibility with evolving software platforms, and ease of use make it ideal for onboarding new technicians without sacrificing inspection quality.
Real-world usage continues to validate its benefits; PROtect has already identified developing issues during inspections that older models would have missed.
Conclusion
The FLIR G609 has redefined what’s possible in IR furnace inspections. With Jason Czajkowski’s expertise guiding implementation at PROtect, the new technology delivers unparalleled image quality, user-friendly controls, and efficient software integration.
As the refining and petrochemical industries demand ever-higher standards of safety and uptime, PROtect’s forward-thinking approach ensures its clients stay ahead of the curve.
