Hydrocarbon transfer pipelines that passing/traversing across protected areas have always the risk of sudden failure due to unseen internal corrosion causing damage to the surrounding environment. Therefore, it is necessary to maintain the integrity of hydrocarbon transfer pipelines especially, aged pipelines in order to minimize the risk of its failures, avoid oil spill, protect the environment from pollutants and achieve a proactive pipeline failure control. This paper presents a pipeline risk assessment program that was designed to manage corrosion, control pipeline's failures and to assure a renovated pipeline system. This program includes practical techniques to 1) refurbish a doubtful pipeline, 2) determine exact condition & remaining life of a pipeline and 3) to make active pipeline maintenance. This technique is successfully implemented in GUPCO Oil Company and proved its capability to be a powerful tool to evaluate & maintain the overall integrity/strength of GUPCO pipeline's systems. It is simple now for pipeline operators to identify areas of greatest impact to the environment & safety and to respond with the necessary course of actions to remedy the deficiencies. Thus, they succeeded in maximizing economic returns for pipelines-owners, protecting the safety of employees/community, minimizing risk to the environment and finally complying with the laws and regulations of Egypt.

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