BROEN BALLOMAX User manual

QUALITY ASSURANCE
BALLOMAX
®
API 6D CERTIFIED
BALL VALVES
Double Block & Bleed, with
Emergency Sealant Injection Ports
Technical Manual
Revised: Aug, 2019

BALLOMAX
®
API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
2 Rev 08/2019
Contents
I. INTRODUCTION............................................................................................3
Technical Manual Release date.....................................................................4
BROEN A/S and BROEN Inc.........................................................................5
The Product ...................................................................................................5
Code and Compliance ...................................................................................6
Applicable Standards and Specifications.......................................................7
II. QUALITY ASSURANCE AND CONTROL....................................................11
The BROEN Quality Management System..................................................12
ISO 9001 certificate .....................................................................................13
API 6D certificate .........................................................................................14
III. ENGINEERING DETAILS ............................................................................15
Valve Data Sheet.........................................................................................16
Valve components and materials.................................................................17
The API 6D nameplate ................................................................................20
Extract from Catalogue ................................................................................21
IV. TESTING AND CODE COMPLIANCE .........................................................25
Test Procedure according to API-6D, section 5, DIN 3230, section 3, and
ISO 5208......................................................................................................26
Hydrostatic Shell Test..................................................................................26
Hydrostatic Seat Test ..................................................................................26
Air seat and stem test according to DIN3230 (ISO 5208) ............................27
Valve documentation and example of a test certificate................................28
V. STANDARD VALVE PROCEDURES...........................................................29
Valve preservation and storage ...................................................................30
Valve handling, transportation, and shipment..............................................30
Standard installation procedures .................................................................31
Testing of field welds ...................................................................................33
Hot tapping ..................................................................................................34
Valve operations ..........................................................................................35
Valve maintenance ......................................................................................35
Recommended valve lubrication procedure.................................................35
Troubleshooting...........................................................................................37

BALLOMAX
®
API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
3 Rev 08/2019
I. INTRODUCTION

BALLOMAX
®
API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
4 Rev 08/2019
Technical Manual Release date
BROEN
BALLOMAX
®
All information contained in this manual is the exclusive property of
BROEN Inc. Any reproduction or use of the calculations, drawings,
photographs, procedures, or instructions, either expressed or implied, is
forbidden without the written permission of BROEN Inc. or its authorized
agent.
Initial Release: June 16, 1997
Latest revision: August, 2019. Prepared by: Tommy Peddycord
Approved By:
Mogens Laursen, CEO BROEN A/S
BROEN A/S
Ben Marchisio, President
BROEN Inc.
Copyright© 1997 all rights reserved
By BROEN Inc.
BROEN Inc.
27657 Commerce Oaks Drive
Oak Ridge North (Houston ) TX 77385
Phone: [phone]
www.broen.us

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BROEN A/S and BROEN Inc.
BROEN A/S was founded in 1948 in Denmark. Today it is part of the Aalberts
Industries Group of the Netherlands. BROEN A/S is a global leader manufacturer
of valves for District Heating and for the Natural Gas Industry.
Recently BROEN A/S acquired Clorius, a manufacturer of products for
temperature and pressure control.
BROEN Inc, Birmingham, Alabama was created in 1995 to provide the North
American market production of Ball Valves to better serve our customers. We
moved to Houston, Texas in 2016 to a new and larger facility, with greater
capacity, to continue to provide fast deliveries, broader product range, and
technical assistance when needed.
The Product
The Flagship products for BROEN Inc. are the BALLOMAX
®
Ball Valves for
Natural Gas Industry. Our API 6D Certified Valves represent the state of the art
for trunnion mounted ball valve technology. The valves are Double Block and
Bleed with emergency sealant injection ports, ANSI 150, ANSI 300, and ANSI
600.

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Code and Compliance
BROEN Inc BALLOMAX
®
API 6D Certified Ball Valves are produced in
accordance with API 6D and strictly adheres to API Monogramed requirements.
Conforming to requirements of API Q1 and ISO 9001 Quality Management
Systems. All Ballomax valve are fully traceable, meet or exceed the requirements
of ANSI dimensions, Fire Tested to ISO FT (10497) harmonized to API 6D 6FA
General Standard, and API 607 standards for primary soft seat, MSS-SP 72, and
DOT Title 49, part 192. Each valve produced are Hydrostatically Tested per API
6D with a supplementary air test per ISO 5208. Test Certificates are available for
every valve. We operate under the API license # 6D-0378.

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Applicable Standards and Specifications
The latest edition of the following specifications and standards will be used to
establish the basic requirements referenced throughout this pre-qualification for
the specific type of valves being inspected and tested.
Unless specifically designated by date, the latest edition of each publication shall
be used together with any amendments, supplements, or revisions.
API - AMERICAN PETROLEUM INSTITUTE
Spec. Q1 Specification for Quality Programs.
Spec. 6D Specification for Pipeline Valves.
6 FA Specification for Fire Test for Valves.
Std. 598 Valve Inspection and Testing.
Spec. RP6F Recommended Practice for Fire Test for Valves
Std. 607 Fire Test for Soft-Seated Quarter- Turn Valves.
ANSI - AMERICAN NATIONAL STANDARD INSTITUTE
B 16.5 Pipe Flange and Flanged Fittings.
B 16.10 Face-to-Face and End -to-End Dimensions of Valves.
B 16.25 Butt Welding Ends.
B 16.34 Valves-Flanged, Threaded and Welding Ends.
B 31.3 Chemical Plant and Petroleum Refinery Piping.
B 31.4 Liquid Transportation Systems for Hydrocarbons, Liquid
Petroleum Gas, Anhydrous Ammonia and Alcohols
B 31.8 Gas Transmission and Distribution Piping Systems.
ASTM - AMERICAN SOCIETY OF TESTING MATERIALS
ASTM VOLUME 01.01 Steel Piping, Tubing, Fitting.
ASTM VOLUME 01.02 Ferrous Casting, Ferroalloys.
ASTM VOLUME 01.05 Steel Bars, Forgings, Bearings, Chain, Springs.
ASME - AMERICAN SOCIETY OF MATERIALS ENGINEERS
ASME B 1.20.1 Pipe Thread and Flanged Fittings.
ASME B 16.5 Steel Pipe Flanges and Flanged Valves and Fittings.
ASME B 16.11 Forged Steel Fitting, Socket Welding & Threaded.
ASME B 16.20 Ring Joint Gasket & Grooves.
ASME B 16.25 Butt Welding Ends.
ASME B 16.34 Valves Flanged, Threaded and Welding Ends.
ASME B 16.47 Large Diameter Steel Flanges, NPS 26 through NPS 60.
ASME Sect. V Non-destructive Examination.
ASME Sect. VIII Rules for Construction of Pressure Vessels (Division 1).
ASME Sect. IX Welding and Brazing Qualifications.
IS0 - INTERNATIONAL STANDARD ORGANIZATION
228 Part 1 Pipe Threads, Designation, Dimensions and Tolerances.
5208 Pressure Testing to Valve 17121 Flanged Steel Ball Valves.
5210 Industrial Valves-Multi- Turn Valve Actuator Attachments.

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5211-1 Partial Turn Valves Actuator Attachment-Part 1 : Flange
Dimensions
5752 Face to Face and Center to Face Dimensions.
10497 Testing of Valves: Fire Type Testing Requirements.
MSS - MANUFACTURERS STANDARDIZATION SOCIETY
SP 25 Standard Marking Systems for Valves, Fittings, and Flanges.
SP 44 Steel Pipe Line Flanges.
SP 45 Bypass and Drain Connections.
SP 53 Quality Standard for Steel Castings for Valves, and Flanges.
SP 61 Pressure Testing of Steel Valves.
SP 72 Ball Valves with Flanged of Butt-Welding Ends for General.
SP 76/001 Surface Finish of Flange Gasket Contact Faces.
SP 77/302 Materials, Non-Destructive Examination and Certification.
SP 77/315 Electro- Nickel Plating for Improved Corrosion Resistance.
SP 77/316 Electro- Nickel Plating for Improved Wear Resistance.
SP 82 Valve Pressure Testing Methods.
SP 84 Steel Valve Socket Welding and Threaded.
SP 92 Valve User Guide.
SP 93 Quality Standard for Steel Castings and Forgings for Valves.
SP 94 Quality Standard for Ferritic and Martensitic Steel Castings.
NACE - NATIONAL ASSOCIATION OF CORROSION ENGINEERS
* NACE Materials are optional and must be specified on purchase orders.
MR-01-75 Sulfide Stress Cracking Resistant Metallic Material.
MT -01-77 Laboratory Corrosion Testing of Metals for the Process Industries
TEST & INSPECTION SPECIFICATIONS
HYDROSTATIC/PNEUMATIC PRESSURE TEST (SHELL, SEAT)
API STD 598 Valve Inspection and Testing.
ANSI B 16.37 Valves -Hydrostatic Test.
ANSI B 16.104 Seat Leakage Test
ANSI/FCI 70.2 Seat Leakage Class for Valves.
BS 5146 Inspection and Test of Valves.
BS 6755 Part 1 Pressure Test.
MSS SP-61 Pressure Testing of Steel Valves.
MSS SP-82 Valve Pressure Testing of Methods.
ISO 5208 Industrial Valves Pressure Testing.
VISUAL & DIMENSIONAL INSPECTION
ANSI B 16.5 Steel Pipe Flanges and Flanged Valves and Fittings.
ASME B 16.47 Large Diameter Steel Flanges, NPS 26 through NPS 60.
API 605 Large Diameter Carbon Steel Flanges.
ANSI B 16.25 Valves - Flanged. Thread and Welding End.

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ANSI B 16.10 Face-to-Face and End -to-End Dimension of Valves.
ANSI B 16.34 Valves - Flanged and Butt-Welding Ends.
MSS SP-6 Standard Finishes for Contract Faces of Pipe Flanges,
Connection End Flanges of Valves and fittings.
MSS SP- 25 Standard Marking System of Valves, Fittings, etc.
MSS SP- 55 Quality Standard for Steel Castings - Visual Method.
MSS SP- 72 Ball Valve - Port Type, Full Bore, Regular Bore.
BS 1560 Circular Flanges for Pipes, Valves and Fittings.
BS 2080 Specification for Face to Face, Center to Face, End to End,
and Center to End Dimension of Valves.
NONDESTRUCTIVE EXAMINATION (NDE. NDT)
ANS1816.34 Valves- Flanged, Thread and Welding End
ASTM E94 Recommended Practice for Radiographic Testing.
ASTM E165 Practice for Liquid Penetrant Inspection.
ASTM E709 Practice for Magnetic Particle Inspection.
ASTM E114 Practice for Ultrasonic Inspection.
ASTM E142 Standard Method for Controlling Quality of Radiographic
Testing.
ASME Sec. V Nondestructive Examination.
MECHANICAL TEST
ASTM A370 Specification for Test Methods and Definitions for
Mechanical Testing of Steel Products.
SULFIED STRESS CRACKING RESISTANCE TEST
NACE-MR-O1-75 Metalic Materials for Sour Oil & Gas Field Equipment.

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®
API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
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BROEN
BALLOMAX
®
API Q1 Certified
ALL WELDED BALL VALVES
Double Block and Bleed with
Emergency Sealant Injection Ports

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II. QUALITY ASSURANCE AND CONTROL

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The BROEN Quality Management System
BROEN VALVE GROUP was originally certified according to EN 29001/ ISO
9001 on September 9, 1994.
Audits are periodically performed to ensure certification validity.
BROEN VALVE Group’s Quality Management System is now described by an
electronic document, accessible to all relevant employees, continuously updated
and improved, and used for both internal and external audit purposes.

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ISO 9001 certificate

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API 6D certificate

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III. ENGINEERING DETAILS

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Valve Data Sheet
Specifications Required: API-6D latest edition; MSS-SP-72; DOT 192 title 49;
DOT 192-145
Valve Size: ¾ inch – 36 inch
Port: Full Port
Traceability: all valves with individual Serial Numbers
Service: Natural Gas Distribution and Compliance Pipeline, Bypass lines, Hot
Tapping for Natural Gas Service. Transmission Service
Flow direction: fully bi-directional
Location: Above Ground and Below grades for direct burial.
Maximum Operating Pressure: 285 PSI (ANSI 150), 740 PSI (ANSI 300), 1480
PSI (ANSI 600)
Maximum Field Test Pressures: (see API-6D Paragraph 3): 1.5 times MAOP
with valve in Fully Open position, 1.1 times MAOP with valve in full closed
position.
Pressure Class: ANSI 150, ANSI 300 and ANSI 600
Maximum Service Temperature: 212°F (100°C)
Minimum Service Temperature: -40°F (-40°C)
Service: Natural Gas or Propane
Type of Valve: Double Block and Bleed with Emergency Sealant Injection Ports
Valve, Trunnion Mounted, Lubricated, Quarter Turn with multi-turn Gear
Operator.
Torque information, Pressure Loss information (Cv), weight data, and any other
additional technical information is either included on the drawing for each
individual valve or will be provided upon request.

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API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
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Valve components and materials
Body
The BALLOMAX
®
API Certified Ball Valves can be manufactured in two versions:
•all welded construction, designed and built to attain maximum strength
and minimum weight, minimizing the potential leak paths.
•Three piece bolted body.
The body is manufactured of either heavy wall seamed carbon steel pipe, Cast
Steel Pipe, A-105 Forged Steel, or A350 LF2 material depending on Pressure,
Media, and or Temperature. The valve is suitable for both above ground and
direct buried applications.
Ball
The ball is full port (API 6D), made of High strength Carbon Steel A-350 LF2,
ground to specific tolerances, with Electroless Nickel Plating (ENP). Additional
special materials available upon request.
Trunnion mounted ball design
All BROEN Ballomax API 6D certified valves are all Trunnion Mounted type.
The sealing principle is that the trunnion supported ball surface mates with the
piston spring loaded HNBR seats on both sides of the Ball creating a double
blocking design. This is especially desirable in High Differential pressure
applications to eliminate high torque in the operations of the valve. BALLOMAX
Standard Trunnion Mounted valves come equipped with a Bleed / Drain port to
vent the body of the valve in 100% open or closed position.
Vent and Drain
A vent port on the upper quadrant and drain port in the lower quadrant are
provided to be able to test the integrity of sealing and drain the valve body, in the
full open or full closed position, or to remove any external materials from the
seats area.
Seat
We offer two seat designs:
•SPE, single piston effect, with self-relieving seats: an over-pressure in the
body cavity is release across the seat on the side of lower pressure
(typically downstream).
•DPE, double piston effect: an over-pressure in the body cavity is trapped
and not released. The installation of an external relief system is
recommended.
Both seats are PMSS (Primary Metal and Secondary Soft Seats), where the
primary metal seats protects the soft materials from external materials in the
fluid, thus ensuring extended valve lifespan. The soft HNBR o-ring ensures
bubble tight operations, even at cold temperature (-40°F/-40°C).

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Metal-to-metal seats are available upon request.
All seats are spring loaded.
Fire safe design is ensured by a graphite ring and the metal to metal primary
seal.
Lubrication system
The BALLOMAX API 6D certified valves are provided with Emergency Sealant
Injection ports.
Our standard design includes an internal check valve located after the Injection
fittings (both threaded into the body) to ensure no leakage, even after removal of
the Injection fitting.
The lubrication system is designed to accomplish three goals:
I. Flushing: remove any external materials from the interstice between the
ball and the seat;
II. Lubrication: reduce the friction between ball and seat, minimizing the
torque required to operate the valve;
III. Emergency sealing: allow for sealants to be pumped into the seating area
to stop leaks.
End connections
Weld Ends are in A105, S355 J2, or A350 LF2 machined per ANSIB16.25,
machined to industry standards wall thicknesses. At the customer’s request the
ends can be counter bored to match piping.
Flanged Ends are in ASTM A 105 Forged Steel per ANSI B16.5.
Anti-static device
All BROEN Ballomax API 6D valves come with an anti-static device on their stem
in order to avoid sparks and prevent problems when handling flammable fluid, in
compliance with API 6D requirements.
Stem material and sealing design
The Stem is made of X20Cr13/AISI 420 High strength steel, Electroless Nickel
Plating (ENP).
The Stem sealing is provided by a four level barrier, using two Upper HNBR o-
rings, and a Lower FKM (Viton
®
) o-ring. The stem sealing design also includes a
PTFE stem packing.
The stem assembly is designed including an anti-blow out system in
compliance with API 6D requirements.
ISO mounting plate
All Standard Trunnion Mounted Valves require Gear Operators or Actuators. We
offer both, Horizontal Gear or Vertical Gear Operators properly sized to optimize
operations. Full range of actuators available, upon request.
Paint

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Standard paint is a Non-Toxic water based prime. BROEN can provide specialty
coatings in house such as 3M 323, or Coal Tar Epoxy. Contact us for any special
coating requirement you may have.
Gear Operators
Valves can be supplied with Horizontal Gear with Hand-wheel or Vertical Gear,
both with 2” Ductile Iron nut. All gears are sized to optimize performance.
Suitable for above ground or Direct Burial.
Actuators
Valves can be supplied with any type of actuator. Please provide all relevant
actuator specs and controls requirements when requesting an automated valve
package.

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API 6D Certified Trunnion Mounted Ball Valves - Technical Manual
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The API 6D nameplate
Every BALLOMAX API Certified valve has a permanently affixed API licensed
Label per API 6D code. It provides you with critical information permanently
stamped to insure no misapplication of correct valve pressure rating is used for
the application that it is intended:
A separate nameplate includes the API monogram, the unique API number
assigned to BROEN and the manufacturing date:
This is the unique Serial Number used by BROEN to ensure valve
identification and traceability