To ensure the safety of heated waxy crude oil pipeline with in-line rehabilitation, the allowable exposed length and the impending length of the pipe will be respectively determined by using the thermal and hydraulic calculation method for buried heated crude pipeline and Safety Assessment for In-service Pressure Vessels with Defects. In addition, with the elastic foundation beam model, safety measures of backfilling with sand compacted are proposed based on the calculation of the pipe bending stress distribution after backfilling. In this research, a software package has been developed to compute the reasonable exposed length and the impending length of the pipeline in any position and operating condition. The obtained results with comprehensive considering most of key factors are reliable and reasonable which brings the advantages of safety and economy. The technical parameters and manuals obtained have been successfully applied to guide the in-line rehabilitation of China’s Northeast pipeline system.

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