Development of an Integrated Framework for Condition-Based Maintenance and Industry 4.0 in Oil and Gas Plants

This thesis comprehensively explores the integration of Industry 4.0 technologies with Condition-Based Maintenance (CBM) in the oil and gas sector, focusing specifically on its application within the Nigerian context. The research is grounded in a systematic review of foundational elements, including the industry background, core research questions, objectives, and the thesis's academic and industrial contributions. Emphasis is placed on optimizing maintenance procedures in production facilities to strike a balance between reliability and cost-efficiency to surpass performance and safety standards. An extensive literature review forms the basis of this study, delving into the evolution of maintenance strategies, with a particular focus on CBM. The research highlights the critical role of CBM in enhancing productivity by preventing equipment downtime, particularly within the dynamic and complex operations of the oil and gas sector. The study then examines the integration of Industry 4.0 within this sector, underscoring the need for tailored Industry 4.0 Maturity Models (MMs) to meet the sector's unique requirements. Methodologically, the research employs a mixed-methods approach, combining quantitative and qualitative paradigms. This includes an extensive literature review, surveys, and the Delphi method to ensure the comprehensive verification and validation of the proposed integrated framework for CBM and Industry 4.0. The empirical phase of the study employs action research, detailing the practical application of the framework in an operational oil and gas field in Nigeria. The research identifies principal challenges in integrating Industry 4.0 technologies with CBM strategies, such as budgetary constraints, limited resources, and inadequate executive support. It also provides a detailed analysis of the barriers to effective integration and proposes actionable insights for industry stakeholders to improve operational performance. A significant contribution of this thesis is developing a model and framework. The model is complemented by an online assessment tool, facilitating organizations in evaluating their Industry 4.0 readiness and guiding them through the adoption process. The model and tool are validated through a Delphi study and tested empirically, demonstrating their applicability and effectiveness. The thesis concludes by synthesizing the entire research journey, from conceptualization to empirical validation. It articulates the theoretical and practical implications of the work, acknowledges its limitations, and suggests directions for future research. The research achieves its objectives by substantially contributing to the knowledge base on integrating Industry 4.0 into CBM practices within the oil and gas sector, demonstrating high academic rigour and practical relevance.