The Khurais Arabian Light (AL) Crude Increment Project will install facilities to enable production of an additional 300,000 barrels per day of stabilized AL crude oil. The project scope includes an additional seawater supply pipeline (48 inch x 73 km) between Ain Dar and Khurais to support the reservoir injection capacity requirement for Khurais fields. The project scope also includes a satellite gas-oil separation plant (GOSP) facility in the vicinity of the Abu Jifan and Mazalij fields southwest of Khurais, along with three trunk line sections — 7 km of 12 inch, 31 km of 16 inch and 24 km of 18 inch — and 90 km each of 26 inch and 16 inch gas transfer and wet crude transfer pipelines to Khurais Central Processing Facility (KhCPF). To reduce the project capital cost, a detailed technical evaluation of the complete pipeline system was performed, which included the evaluation of minimum acceptable wall thickness calculation and stress analysis. Based on the evaluations, the project design team was able to optimize the pipelines’ wall thicknesses, which has resulted in significant cost savings. This paper describes the technical evaluations that were completed to optimize the wall thickness for the pipelines.