Infrared thermography is increasingly crucial for safety and efficiency in the petrochemical and refining industries. Jason Czajkowski, the IRT Thermography Manager at PROtect, is at the forefront of integrating state-of-the-art technology into furnace inspections.
A certified Master Thermographer and CWI, Czajkowski and his team have adopted FLIR's latest furnace inspection camera, the FLIR G609, transitioning from the previously relied upon GF309. This shift signifies a step forward in managing high-temperature industrial settings.
Resolution enhancements
FLIR GF309 has long served the industry, but its 320 × 240 pixel resolution limited image clarity
The FLIR GF309 has long served the industry, but its 320 × 240 pixel resolution limited image clarity, impacting the detection of subtle temperature variations from a distance.
The FLIR G609 offers a resolution of 640 × 480 pixels, offering inspectors more than four times the pixel clarity. This advancement aids in identifying minor issues like coke buildup and flame impingement at an early stage, which is critical in preventing major failures.
Advanced features of the G-Series
Beyond resolution, the G609 incorporates advanced features that modernise inspections. It includes a redesigned heat shield requiring only a single screw for attachment, which enhances safety during live furnace assessments.
Its intuitive 4-inch touchscreen interface supports ease of use, even when operators are wearing gloves. Czajkowski highlights the utility of the 1-Touch Level/Span feature, which simplifies image contrast adjustments, allowing inspectors to focus more on data capture.
The camera's custom furnace lens, calibrated to provide clear thermal imagery through flames and refractory, marks a significant upgrade over earlier models. Czajkowski states, "It’s not just about seeing through the flame; it’s about seeing what matters behind it."
Comprehensive software integration
PROtect utilises the Route Creator plug-in to pre-plan reviews, designating check points
When combined with FLIR's Thermal Studio Pro software, the G609 becomes a comprehensive inspection and reporting tool.
PROtect utilises the Route Creator plug-in to pre-plan inspections, designating inspection points and optimal routes. This functionality ensures thorough coverage during site visits, minimising the risk of oversight.
Thermal Studio Pro improves post-inspection efficiency, offering batch processing of images and standardised report templates. This functionality reduces the reporting time from hours to minutes. "The software enables consistency and speed," asserts Czajkowski, highlighting the higher report turnaround times achieved.
Long-term investment and practical validation
The G609 represents a strategic investment in the future, designed with durability and software compatibility in mind. It simplifies training for new technicians while maintaining high inspection standards. Field usage has confirmed its capabilities, with PROtect identifying nascent issues that older equipment might have overlooked.
By adopting the FLIR G609, PROtect has set a new benchmark in infrared furnace inspections. Under the guidance of Jason Czajkowski, the integration of this advanced technology not only provides superior image quality and user convenience but also enhances inspection processes through efficient software tools.
As demands for safety and operational reliability grow in the refining and petrochemical sectors, PROtect's proactive approach positions its clients to navigate future challenges effectively.
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 recognised 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 modernise 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 emphasises 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.
