From normative compliance to operational reality: An ergonomic study of valve design for offshore platforms

BackgroundThe design of valves in continuous process industries, such as on Floating Production, Storage, and Offloading (FPSO) platforms, often shows a significant gap between regulatory standards and the practical needs of operators and maintainers. While integrating ergonomics in the early project stages can improve efficiency and safety, a disconnect persists between a design's formal compliance and its usability.ObjectiveThis study aims to analyze the ergonomic challenges and systemic barriers that limit the integration of operational knowledge in the valve design process on FPSO platforms.MethodsA qualitative, descriptive case study was conducted on two FPSO platforms operating on the Brazilian coast between September 2022 and March 2024. Data were collected from multiple sources, including technical document analysis, interviews, participatory observation, and valve design review sessions. Activity ergonomics guided the research to integrate user knowledge into design specifications.ResultsThe research identified that the rigid application of valve categorization criteria and a lack of adaptation to local anthropometric data lead to a design that does not fully meet user needs. Case studies show that compliance with standards fails to guarantee usability, resulting in design decisions that prioritize one component at the expense of another's accessibility.ConclusionThe effective integration of ergonomics and operator knowledge in early stages is essential for safer and more efficient design, but participation alone is insufficient. This study concludes that project processes and tools must be enhanced to systematically transfer operational knowledge to engineering, aligning normative requirements with actual work demands.