In an era where industrial competitiveness is deeply tied to operational reliability and energy efficiency, optimizing thermal systems has become a business imperative. The Heater and Heat Exchanger Troubleshooting Skills course by Pideya Learning Academy offers a comprehensive exploration of the critical systems that drive heat transfer processes in energy-intensive operations. Designed for professionals in refining, petrochemicals, power generation, and related sectors, this training equips participants with the essential knowledge to identify performance bottlenecks, troubleshoot issues, and implement strategies for sustained operational efficiency.
Heaters and heat exchangers are integral to nearly every stage of industrial processing. Globally, thermal energy accounts for over 70% of industrial energy use, with heat exchangers alone responsible for up to 60% of all energy transfer tasks in sectors such as oil and gas, food processing, and chemicals. According to the International Energy Agency (IEA), improving the efficiency of heat exchangers could cut industrial energy consumption by up to 20%, while the U.S. Department of Energy notes that poorly managed fired heaters contribute significantly to over 40% of combustion-related emissions in manufacturing plants. These figures underscore the importance of developing robust operational and diagnostic skills to mitigate energy losses, reduce emissions, and avoid unplanned downtime.
To address these pressing industry needs, Pideya Learning Academy has carefully designed this Heater and Heat Exchanger Troubleshooting Skills course to deliver both depth and relevance. The training provides a structured understanding of the principles of heat transfer—including conduction, convection, and radiation—while diving deep into the behavior of thermal systems under different load and operational scenarios. Participants will study flow arrangements such as counter-current and parallel-flow configurations, gain familiarity with materials selection, understand common failure modes, and evaluate system responses to varying process conditions.
Throughout the course, learners are introduced to industry-specific challenges including fouling, thermal fatigue, burner misalignment, flame instability, and hotspot development. Special focus is given to troubleshooting techniques for both shell-and-tube and air-cooled exchangers, as well as horizontal and vertical heater configurations. Participants will explore structured methodologies to identify root causes of performance issues, implement preventive strategies, and align their practices with evolving regulatory and operational standards.
Among the key highlights of the training are:
Comprehensive analysis of flow patterns and pressure drop behavior in different exchanger designs.
Fault detection strategies for tube-side and shell-side anomalies including corrosion, erosion, and scale buildup.
Procedures for safe isolation, inspection, and recommissioning of thermal systems.
Evaluation techniques for combustion efficiency, burner performance, and flue gas temperature profiles.
Step-by-step methodologies for heater start-up and shutdown in accordance with operational safety norms.
Insights into tube rupture risks, overheating, and refractory failures, with preventative maintenance frameworks.
Real-world industrial case references that demonstrate root cause analysis and failure prevention.
This training is uniquely positioned to help professionals integrate operational knowledge with diagnostic reasoning, ensuring consistent system performance while meeting environmental and safety compliance benchmarks. Rather than limiting participants to theoretical exposure, Pideya Learning Academy emphasizes real-world application through scenario-based insights and peer learning environments. By mastering the intricacies of heater and heat exchanger systems, participants will be empowered to make confident, impactful decisions that safeguard assets and optimize throughput.
Whether you are an operator overseeing day-to-day functions or an engineer responsible for performance analysis, the Heater and Heat Exchanger Troubleshooting Skills course will elevate your understanding and transform your approach to thermal systems. Delivered by seasoned industry experts, this program enables participants to contribute meaningfully to plant safety, reliability, and sustainability—key priorities in today’s industrial landscape.

Key Takeaways:

• Comprehensive analysis of flow patterns and pressure drop behavior in different exchanger designs.
• Fault detection strategies for tube-side and shell-side anomalies including corrosion, erosion, and scale buildup.
• Procedures for safe isolation, inspection, and recommissioning of thermal systems.
• Evaluation techniques for combustion efficiency, burner performance, and flue gas temperature profiles.
• Step-by-step methodologies for heater start-up and shutdown in accordance with operational safety norms.
• Insights into tube rupture risks, overheating, and refractory failures, with preventative maintenance frameworks.
• Real-world industrial case references that demonstrate root cause analysis and failure prevention.

• Comprehensive analysis of flow patterns and pressure drop behavior in different exchanger designs.
• Fault detection strategies for tube-side and shell-side anomalies including corrosion, erosion, and scale buildup.
• Procedures for safe isolation, inspection, and recommissioning of thermal systems.
• Evaluation techniques for combustion efficiency, burner performance, and flue gas temperature profiles.
• Step-by-step methodologies for heater start-up and shutdown in accordance with operational safety norms.
• Insights into tube rupture risks, overheating, and refractory failures, with preventative maintenance frameworks.
• Real-world industrial case references that demonstrate root cause analysis and failure prevention.