Infrared thermography has become an indispensable tool in petrochemical and refining operations. In this article, Jason Czajkowski, a certified master thermographer and CWI at engineering services firm PROtect, explains how his company uses the new FLIR G609 to transform furnace inspections in high-heat industrial environments.
Left: Enhanced 640-resolution detector reveals fine thermal details for faster, more accurate inspections. Right: Redesigned cold filter enables clear visibility through flames, even in the harshest conditions.FLIR
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.
Side-by-side comparison of FLIR GF309 (left) and FLIR G609FLIR
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 emphasized 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.
"It’s not just about seeing through the flame, it’s about seeing what matters behind it," Czajkowski said.
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," Czajkowski said. "We can now deliver high-quality reports faster than ever before."
Czajkowski noted 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.
