Max Pressure · Burn-Through Risk · Recommendations
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Hot Tap Welding Calculator
Evaluates minimum wall thickness and welding parameters for safe hot tapping on pressurized pipelines. Ensures burn-through prevention per ASME B31.4/B31.8 and API 1104 welding standards.
Calculation Mode:
Pipe Specifications
in
in
in
Material & Standards
Operating Conditions
°F
Burn-Through Risk
in
kJ/inch
Welding Recommendations
in
Max Pressure Results
Max Safe Pressure
- psig
Allowable Stress- psi
Hoop Stress @ Max P- psi
Stress Ratio- % SMYS
Burn-Through Risk
Risk Level
-
Burn-Through Param.-
Max Heat Input- kJ/inch
Welding Recommendations
Electrode
-
Preheat Temp-
Technique-
Passes-
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Formula (Hoop Stress)
σh = (P × D) / (2 × t)
σh = Hoop Stress
P = Internal Pressure
D = Outside Diameter
t = Wall Thickness
Standards & References
API RP 2201 Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries
ASME B31.4 / B31.8 Pipeline Transportation Systems for Liquids and Gas
API 1104 Welding of Pipelines and Related Facilities
Important Notes
Hot tapping and welding on in-service pipelines are high-risk activities.
Always follow established procedures and safety guidelines.
Burn-through risk is influenced by wall thickness, heat input, and flow conditions.
Ensure proper material compatibility and welding procedures are followed.