A maintenance overhaul should not only begin after a failure. Indications can include increasing vibrations or temperatures, altered electrical readings, abnormalities in bearings and windings, and recurring operational disturbances. We analyze these observations together with operating time, load profile, and existing diagnostic history. This allows us to plan the scope of the overhaul in a timely manner and combine it with a suitable plant shutdown.

The decision is based on the actual condition of the stator, rotor, windings, insulation, and mechanical components. We assess whether damage is localized or whether aging and consequential damage affect larger areas. Availability, downtime, spare parts availability, and expected future use are also factored into the assessment. The result is a technically sound repair plan rather than a blanket overhaul.

A generator can behave differently under load than when stationary or idling. Therefore, during load testing, we check whether electrical and mechanical characteristics, as well as the control system, function reliably under the agreed-upon conditions. This allows us to identify any anomalies in temperature, vibration, or control behavior before recommissioning. The scope of testing depends on the generator's power output, design, and testing methodology.

For thorough preparation, we require type and performance data, drawings, revision history, current measurements, known symptoms, and the operating profile. Additionally, we clarify accessibility, lifting and transport options, safety requirements, the available timeframe, and the desired acceptance criteria. This allows us to plan personnel, testing equipment, spare parts, and any necessary workshop work before the shutdown.

We assess the nature and development of the anomaly, stress, temperature, vibration, electrical measurements, and potential consequential damage. A stable, explainable value can initially be monitored closely, while rapid changes or safety-relevant findings require immediate action. The decision is always based on the specific machine and its operational criticality.