40 Years at the Energy Frontier: High-Risk SIMOPs, Control Room Mastery, and the Human Standard
When managing high-voltage refineries, offshore platforms, or 1,200 MW power plants, technical specs only tell half the story. The rest comes down to operational discipline, isolation protocols, and field culture.
With 40 years across Sarawak Shell, PETRONAS Carigali, POSCO E&C, and mega-projects in Africa and the Philippines, Dr Khaulid Abdul Manap knows high-risk offshore operations inside out. From directing simultaneous operations (SIMOPs) on live platforms to running 200,000- barrel-a-day crude terminals, he has seen what keeps industrial assets safe—and what causes them to fail.
1. Navigating SIMOPs: Live Production Meets High-Risk Construction
Managing Simultaneous Operations (SIMOPs) means balancing heavy construction, hot work, and lifting alongside live, pressurized hydrocarbons.
"SIMOPs isn't just about scheduling tasks—it's about managing intersecting risks," Dr Khaulid explains. "You can have hot work welding, heavy crane lifting, and excavation happening all at once. Danger is waiting on top if you don't coordinate daily."
From major rejuvenation campaigns to Shell Philippines’ Malampaya project, Dr Khaulid relies on three non-negotiables:
• Daily Alignment Meetings: Construction, maintenance, and medical teams map spatial hazards and escape routes every morning.
• Strict LOTO & Isolation Barriers: When transitioning to commissioning, Lockout/Tagout protocols must be enforced without compromise as live energy enters.
• Site-Wide Orientation: No contractor enters a live zone without specialized intrusive work and LOTO training.
2. Control Room Operations: Precision Under Pressure
Dr Khaulid spent 16 years climbing from Process Technician to Panelman and Assistant Shift Supervisor at Lutong Refinery, eventually running Port Sudan’s crude terminals. Operating a Central Control Room via Distributed Control Systems (DCS) takes physical intuition and commercial accuracy.
"As a CRO handling crude export loading to international tankers, there is zero room for panic," says Dr Khaulid. "You have to manage gravitational force, step down massive electrical pumps systematically 20 minutes in advance, and continuously verify crude oil quality parameters such as the crude flow rate, total quality transferred loading sequence, pump status, crude density or API gravity basic sediment and water (BS&W)."
Crucially, a great console operator must first be a skilled field technician. Ground-level familiarity with boilers, exchangers, and pumps is what lets an operator make split-second decisions from the panel.
3. Developing Technicians: Moving Beyond Written Tests
As an Executive Production Line Trainer for PETRONAS Carigali, Dr Khaulid coached and assessed technicians across Levels 1 to 5. He draws a clear line between two concepts:
• Ability: Explaining technical concepts on paper.
• Capability: Applying that knowledge safely at the actual equipment under live conditions.
"A competent technician must do more than reproduce steps from memory," Dr Khaulid notes. "I evaluate them at the equipment. I ask them to explain the sequence, point out safety barriers, identify potential abnormal conditions, and justify why every safety step exists."
4. Building a True "Hearts & Minds" Safety Culture
Safety isn't a department; it's a shared mindset that can't be delegated to the HSE team. Real safety culture relies on three practical pillars:
1. Empowered Front-Line Supervisors: Supervisors need leadership and conflict management skills—not just technical knowledge—to verify controls and intervene early.
2. Real Stop-Work Authority: Teams must feel safe stopping work when conditions shift, without fear of retaliation or schedule pressure.
3. Active Buddy Systems: Looking out for colleagues during high-risk tasks isn't an interruption—it's what brings everyone home safely.
Ultimately, a mature safety culture exists when people choose to work safely not because procedures demand it, but because they care about protecting themselves, their team, and their facility.