GE

Masoneilan
ValvFAST Program Overview
Ostrowski
2/25/2016

GE Confidential & Proprietary

This document will describe the requirements and give an overview of the Masoneilan ValvFAST Program, an MRO
based program designed to deliver valves quickly to end users across the globe.
 Masoneilan ValvFAST Program Outline

PROGRAM OBJECTIVE

The ValvFAST Program provides pre-assembled and tested Masoneilan kits for local assembly by
authorized GE users in order to accommodate shorter lead-times for end users demands.

This program utilizes Masoneilan Authorized Repair Centers (MARC’s) to stock and assemble flexible Kit
inventory allowing the best possible delivery possible to meet Customers’ needs.

All ValvFAST Kits have been designed by GE to meet global and local standards (i.e. PED, ANSI, etc) and
produced at certified GE factories prior to distribution to MARC’s for final assembly.

The flowchart below describes a high level overview of the process followed.

Masoneilan ValvFAST Process

User
EndUser

Request or Order
for ValvFAST Valve received
valve
End

YES Sizing data YES

Is valve
Valve is Sized with transferred to VF Is inventory in Inventory is pulled Valve packaged &
ValvFAST fit?
ValSpeq software Configurator for Kit house? for assy & test shipped
Partner

PN’s
ChannelPartner

NO
NO
Channel

Bill of Material
updated in Valve final
aftermarket inspected
database

See BOM Update Procedure

Masoneilan
Masoneilan

Order sent for

Inventory is
factory quote or
ordered
build

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 Masoneilan ValvFAST Program Outline

VALVFAST CHANNEL PARTNER CERTIFICATION

The certification process for a MARC/Channel Partner into the ValvFAST program works in close harmony
with other GE processes to provide a link for complete certification.

 As part of GE “Know Your Customer” (KYC) process a channel partner is first approved by GE,
legally, with a defined territory and set of products (brands to represent). A contract is in
place between the two parties: GE and Channel Partner

 Next a Channel Partner must complete an in-depth audit to become a certified MARC
(Masoneilan Authorized Repair Center) This certification grants them the privilege to repair,
dis-assemble, assemble and conduct on-site services for the Masoneilan product line. An
on-site audit is completed by a GE certified auditor. Regular/periodic audits are completed
for follow-up certification

Once the above criteria are met, then entry into the ValvFAST program can be considered. To ensure all
aspects of the ValvFAST are covered, each channel partner who desires ValvFAST certification is required
to go through a training class on the program. Key elements of the program as outlined in this document
are covered with the key stakeholders of the channel partner, including the Quality Manager and
Operations Manager. After the training has been conducted the Channel Partner can be considered
certified. Evidence of this training shall be documented by the trainer.

Each Channel Partner who is certified from above will be added to a GE “controlled print for ValvFAST
suppliers”. This will grant them access to GE serial plates for the ValvFAST product assembly. (See below)

Each certified ValvFAST channel partner will receive a plaque to demonstrate their fulfillment of the
requirements. Below is a typical plaque

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 Masoneilan ValvFAST Program Outline

VALVFAST PROCEDURE FOR CONFIGURATION THROUGH ASSEMBLY

Configure Valve
Using the “Oracle Configurator” or other tools provided by Masoneilan, choose the kit modules to assemble a valve
as specified by a ValSpeQ sizing sheet. In some cases a sizing calculation may need to be performed using
Masoneilan Sizing software prior to using the configurator.

Find the Kits

Using inventory in stock at the MARC, find the kits needed to produce the configuration determined above. Utilize
the Aftermarket Center in the region to provide missing kits or utilize the MasoneilanLINK to find possible inventory
from other certified MARC’s /Channel Partners.

Assemble Valve
Assemble the valve and use related CES Procedures. By way of the MARC certification technicians have been
previously certified with documented training records.

Perform Leakage Tests

Joint
Body modules are supplied hydrostatically tested per CES-1001. To ensure that the hydrostatic test was
completed check the body module for a hydro stamp ‘E’ or ‘EH’ as shown in CES-1001 section 9 and check
the quality documents for the module serial number for the correct documentation. If the stamp or the
documentation is incorrect a full hydrostatic test must be completed. A joint test must be performed on the
assembled valve per CES-1001 section 6.6 acceptance per CES-1001 section 8.2. If any changes have been
made to pressure-containing components a joint test is not sufficient and a full hydrostatic test must be
performed.
Seat
Perform a seat leakage test in accordance with CES-1002 to the leakage class required by the customer
order.
Packing
Perform a packing leakage test in accordance with CES-1007

Paint Valve
In general only touch up painting is required for ValvFAST products. Touch up paint can be applied using a brush or
by spraying. Painting is done per CES-1036. In addition any areas that are going to be over-coated must be
roughed up using fine sandpaper to ensure good coating adhesion. A touch up Kit including primer and topcoat
offered and details can be found on the ValvFAST tab on Channel Connect under the Aftermarket tab.

Mount Accessories
Mount accessories as shown in the ValSpeQ certified dimensional drawing or per the customer requirement

Fill Out and Attach Serial Plate

Masoneilan serial plates may only be affixed by authorized Masoneilan facilities or authorized ValvFAST channel
partners (MARC’s). The serial plate shall be filled out and attached to the product per CES-1047

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 Masoneilan ValvFAST Program Outline
Complete Final Inspection and Performance Testing
Final inspection and performance testing shall be carried out in accordance with CES-1008. Use the
Assembly Test Data sheet found on Channel Connect – Aftermarket tab – ValvFAST.

BOM Update
Find the valve serial number and go to the BOM Update tool located on Channel Connect. Key in the SN#
of the valve and then select Update BOM. Enter the kits which have been added to produce the final
configuration of the valve. Save the BOM in the tool for future use.

Ship to End User

After all of the above requirements are met the MARC ships the valve to the end user to meet the desired
lead-time needed.

35K CES-105 Hyrdo Test CES 1001

21K CES-107 Assemble Valve & Test Seat Leak Test CES 1002
41K CES-189 Packing Test CES 1007
525/26 CES – 430 Actuator Air Test ES 285
535/536 CES-431

CES 1036
Touch- up valve /
paint as needed

Mount Accessories as See Channel Connect for

other instrument procedures
Required and tests

CAP 108
Fill out Serial Plate &
Attach

CES 1008

Final Inspect

BOM Update
VF Program Guide Update BOM in
MASON Aftermarket
Database

VALVFAST
Package & Ship Ref MARC E.S.
Procedure Index
On Channel Connect
For all procedures

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 Masoneilan ValvFAST Program Outline

TAGGING and SERIALIZATION

All valve body s/a modules have been assigned a serial number (SN#) and this SN# will be carried
throughout the process of the valve build process. It will be applied to the serial plate attached to the
valve. As a result, each valve produced under the ValvFAST program will have a unique SN# and this will
be transferred to the serial plate provided by the MARC/channel partner.

To ensure proper aftermarket support each and every ValvFAST valve will need to be recorded in its “as
built or as supplied” state for the end user. A web-based tool has been developed which will allow the
assembler to update the Bill of Material (BOM) on line. Each ValvFAST valve built by channel partner is
updated on line via the Bill of Material (BOM) Tool.

The BOM updating process will utilize Channel Connect – Spares Quote Tool (SQT) as a means for retrieving
the current SN# for the body sub-assembly. The assembler of the valve will then add to this serial record
the trim kit, actuator and any accessories which make up the final valve configuration. .

Serial plates as a ValvFAST supplier are ordered through Masoneilan approved suppliers. An approved
ValvFAST supplier print shows the specific part number for the serial plate that has been assigned to
MARC/channel partner.

Upon completion of each valve, the assembler will permanently affix the completed serial plate showing
the required information and serial number of the “as-shipped valve”. Instructions for updating a BOM
online using this tool can be found on the Channel Connect Aftermarket tab of the portal.

Below is an example of the pre-assigned serial number which will be affixed to the body s/a when received.
This SN# is the valve ID and will be updated by the ValvFAST assembler, MARC/channel partner using the
BOM Update Tool

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 Masoneilan ValvFAST Program Outline

Example of the ValvFAST serial plate is below. The serial plate will be pre-printed to show the ValvFAST
assembler name and address. All other info on the serial plate information will be completed by the
ValvFAST assembler.

Channel Partner name pre-printed here

GE Serial # goes here

See the below example of how the pre-assigned serial number of the body s/a is entered into the tool. This
produces the BOM and then the ValvFAST kit PN’s can be added to produce the final valve configuration.

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 Masoneilan ValvFAST Program Outline

1. Go to the Aftermarket tab of the Channel Connect. Find On Line Tools and Open
2. Find BOM Update Tool and Open. Insert the serial number you wish to update
3. Once the valve appears in the grey colored bar click on the “select” button on left
4. Go to the “Select Action” box below and select Update BOM
5. A table will appear which will require you to fill out information about the valve.
6. The BOM will appear next. In the top right corner select “ADD” ; an entry box will appear
7. Key in the kits added to the body s/a and hit commit until all kits have been entered.

ValvFAST SCOPE & PRODUCTS

Below is a listing of the ValvFAST products and size ranges. Note that this list may change over time as
more features and sizes are added. Specific PN’s and listings are available to the MARC/channel partner
via the Channel Connect Tool – Aftermarket tab – ValvFAST

All components of the released ValvFAST kits or modules are PED compliant. All pressure containing
components are purchased by GE from GE certified factories per CMS 1040 and all bolting meet required
PED standards.

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 Masoneilan ValvFAST Program Outline
41005 Series ValvFAST Product Scope

41K ValvFAST Product Scope

Product Line 41005 Series (Versions: 413x5, 415x5, 416x5, 419x5)
Valve Size 2” to 8”

Body Material Carbon Steel, Stainless Steel

Pressure Class 150, 300, and 600

Flange Type Raised Face

Temp Range Varies by Model : -29F to 450F (-29C to 232C)

Trim Capacity Balanced Plug Construction Only; NO Pilots

Cage type Linear / Equal Percent / Lo-db / Anti-Cavitation ; Single Stage only; Published CV’s only

Trim Construction
Stem 17-4 PH
Seat Ring 410 SS
Carbon Steel
Plug 17-4 PH
Cage CA6NM Cr Plated
Stem 316 SS

Seat Ring 316 SS HF

Stainless Steel
Plug 316 SS HF

Cage 316 SS Cr Plated

Camflex ValvFAST Product Scope

Camflex ValvFAST Product Scope

Product Line 35002 Series
Valve Size 1" , 1.5", 2", 3", 4", 6" , 8"
Body Material Carbon Steel, Stainless Steel

Pressure Class ANSI 150, 300, and 600 ; ISO PN 20-100

Flange Type Raised Face (Flanged for 150 & 300 class only) , Flangeless

Trim Construction
Shaft 17-4 PH

Carbon Steel Seat Ring 410 Stainless Steel (SS)

Plug 316 Stainless Steel (SS)

Shaft 316 Stainless Steel

Stainless Steel Seat Ring 316, 316 SS Hard-faced Stellite, or Soft Seat available

Plug 316 Stainless Steel Hard-faced Stellite

1" , 1.5", 2" # 4.5 (7-15) 8

Actuator 3", 4" #6 (7-15) GE Proprietary & Confidential
6", 8" # 7 (7-24) or # 9 (7-25)
 Masoneilan ValvFAST Program Outline
21000 Series ValvFAST Scope

21K ValvFAST Product Scope

Product Line 21000 Series
Valve Size .75" to 6"

Body Material Carbon Steel, Stainless Steel

Pressure Class 150, 300, and 600

Flange Type Raised Face

Trim Capacity Full Area & Reduced Area

Trim Type Linear / Equal Percent / Lo-db / Anti-Cavitation ; Full Area only

Seat Ring 410 SS, Plug 410 SS, Stem 17-4 PH

Trim Construction Seat Ring 316 SS, Plug 316 SS, Stem 316 SS
Seat Ring 316 SS HF, Plug 316 SS HF, Stem 17-4 PH

500 Series Regulators

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 Masoneilan ValvFAST Program Outline
ValvFAST kits arrive from Masoneilan in neatly packaged and labeled boxes and are stored at
MARC/channel partner for final configuration at a later time.

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 Masoneilan ValvFAST Program Outline

The combination of kits as shown below are assembled to produce a final 21000 Series valve configuration

The combination of kits as shown below are assembled to produce a final 41005 Series valve configuration

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 Masoneilan ValvFAST Program Outline

The combination of kits as shown below are assembled to produce a final Camflex valve configuration

The combination of kits as shown below are assembled to produce a final 500 Series Regulator

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 Masoneilan ValvFAST Program Outline

ValvFAST Configurator
The ValvFAST configurator has been designed to assist the channel partner in figuring out which kits are
needed to produce a final valve configuration. First, start with the sizing program, Valvspeq, to size the
valve or utilize a previous sizing sheet for the equivalent valve. Getting output from the sizing program
one then proceeds to the configurator to input the data into simple to use drop down menus. The
configurator will then output the kits which are needed to produce the previously sized valve, a ValvFAST
valve.

The configurator is Oracle based. A video for training and use is available on the Channel Connect as
needed

Example of screen shot from Configurator (below)

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 Masoneilan ValvFAST Program Outline

ASSEMBLY & TESTING

All technicians assembling, and testing VAlvFAST valves have received MARC training and passed all
certifications of the ValvFAST program. By virtue of the technician training issued through the MARC
training program, each has been instructed and tested on the valve assembly and testing process. Each
VAlvFAST valve will be documented for purposes of quality. The form below or similar is a requirement for
each ValvFAST valve. This document must be kep on file as noted below in Record Keeping / Retention.

This form can be found on Channel Connect – Aftermarket tab - ValvFAST

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 Masoneilan ValvFAST Program Outline

RECORD KEEPING / RETENTION

Documents which are designated to become records shall be legible, accurate, and complete. Records
shall be indexed and filed in a manner which will permit retrieval of any record within a twenty-four (24)
hour period.

The authorized MARC/Channel Partner will utilize either or both, a paper record system or a paperless
system, thereby making the process for retrieving data fast, easy and green-friendly.

Records requiring correction shall be dated and signed (or initialed) by the individual authorized to issue a
correction at the MARC/Channel Partner. Artificial methods of correction, such as white-out of corrections,
are prohibited.

All records (paper or electronic) shall be stored in folders or binders and placed in an area which minimized
deterioration or damage.

The period of record retention shall be consistent with the guidelines established by GE. Typical related
documents which GE would track and are recommended for retention are noted below.

RECORD RETENTION PERIOD

Customer Purchase Order 3 years
Certified Material Reports 7 years
Hydrostatic/Pneumatic Results 7 years
Seat Leakage Results 7 years
Operational Test Results 7 years
Repair Records/ NDE Records 7 years
Personnel Qualification 7 years
Customer Doc Packages 7 years
Calibration Records Until Recalibrated
Nonconformance Reports 3 years
Corrective Action Requests 3 years
Audit Reviews/ Management Reviews 3 years
Customer Complaints 3 years
Training Records 3 years

TRAINING OF TECHNICIANS
All MARC’s/Channel Partners participating in the ValvFAST Program certifies that a minimum of two
technicians have met and passed the two basic MARC courses offered by GE Masoneilan. Certifications are available
upon request. The technicians have studied and learned the Masoneilan products and the assembly, test and
disassembly of them. These courses have prepared them for the ValvFAST program.
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 Masoneilan ValvFAST Program Outline

MAR001 Course (5 Day Course)

Description: MAR001 provides instruction on Terminology; Control Valve fundamentals; new valve
assembly; and disassembly, inspection, repair, reassembly and testing of the following Masoneilan®
products: 21000/35000/41000 series valves with various standard actuator types and standard
mechanical positioners. Additional instruction includes familiarization with other standard Masoneilan
products and a ValvKeep® overview.

MAR002 Course (5 Day Course)

Description: MAR002 provides instruction on the service and repair of regulators, level controls,
LincolnLog, and cylinder actuators. Additional instruction includes familiarization with SVI II AP, DLT, and
ValScope.

REFERENCE DOCUMENTS

The following is a listing of procedures and standards that are required to be maintained to the latest
issuance date by the participating facility.

ASME / ANSI B16.34 Valves-Flanged, Threaded, and Welded End

ANSI / FCI 70.2 Control Valve Seat leakage
Masoneilan Procedure ES-127 Hydrostatic Testing
Masoneilan Procedure ES-143 Seat leakage Testing
Masoneilan Procedure CES-1008 Operational / Functional Testing

Along with the above GE Masoneilan Corporate Engineering Procedures, CES, are provided on the Channel
Connect tool for use by the approved ValvFAST channel partner. One can access this via Channel Connect
– Masoneilan Aftermarket – CES Procedures tab (below screen shot) This ensures that all procedures are up
to date and to the latest revision

https://www.gefptconnect.com/
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 Masoneilan ValvFAST Program Outline

MARKETING RELATED INFORMATION

It is important to maintain the Brand image of the ValvFAST program and as such there are several pieces
of information for your usage.

Each Body sub-assembly will have attached to it a ValvFAST tag as shown below. This can be secured
from a GE supplier and information of this can be found on Channel Connect. Each Body s/a has this tag
already attached by GE. There are different versions of this tag and one is represented below

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 Masoneilan ValvFAST Program Outline

CHANNEL CONNECT TOOL

Information related to ValvFAST can also be found on the channel connect tool at this link

https://www.gefptconnect.com/

Upon entering the site select the Aftermarket tab and proceed to the label ValvFAST for more detailed
information.

SUCCESS STORIES

There are many success stories that can be shared related to ValvFAST and you can find them on Channel
Connect under Masoneilan Aftermarket / ValvFAST tab. Two that are featured include how Mexico utilized
ValvFAST to meet tight deliveries for some 41000 Series valves. The other is a video from one of our
Channel Partners speaking to the successes they have had in their territory.

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Masoneilan ValvFAST Program Outline

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