Case Study 3 — 48" Crude Oil Transfer Line

The Challenge

The Marsa El Brega Terminal faced a critical constraint on its crude oil export capacity: the existing pipeline infrastructure connecting storage facilities to the marine loading systems was insufficient to meet growing export volumes, creating bottlenecks that limited throughput and affected the terminal's ability to service export tankers efficiently.
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The client required the design, supply and installation of a new large-diameter crude oil transfer line capable of significantly increasing the flow rate between the tank farm and the loading jetty. The project needed to be executed to international pipeline integrity and safety standards, integrated with the existing terminal systems, and delivered with minimal disruption to ongoing export operations.

The VAOS Approach

VAOS managed the project on a full EPC basis, taking responsibility for all phases from detailed engineering through to final commissioning and handover.
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The engineering phase included detailed hydraulic design of the 48-inch transfer line, routing and alignment studies, stress analysis, and full compliance review against applicable international pipeline standards. The design prioritised both operational performance — maximising flow capacity and transfer rates — and long-term integrity, with particular attention to corrosion protection, expansion management and inspection access.
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Procurement covered all major pipeline materials including large-diameter line pipe, fittings, flanges, valves and coating systems, as well as the civil and structural materials required for pipeline supports, crossings and tie-ins to the existing terminal infrastructure.
 
VAOS coordinated the international supply chain to ensure materials arrived on site in sequence with the construction programme.
Construction was carried out by VAOS site crews, encompassing civil works, pipeline installation, welding, external coating and cathodic protection, integration with existing manifolds and loading systems, and full hydrostatic testing. All welding was performed by qualified welders to internationally recognised procedures, with 100% radiographic inspection of critical joints.

Result

The 48-inch crude transfer line was completed, tested and commissioned successfully, delivering a material increase in the terminal's crude oil export capacity. The new pipeline enabled higher transfer rates to the marine loading systems, reducing vessel turnaround times and improving the overall efficiency and reliability of the terminal's export operations. The project was executed without any lost-time incidents and was handed over to the client within the agreed programme.

Impressions