Don’t let small generator issues turn into big repair bills: 5 signs you need a Generator Assessment Program inspection
- Date
- August 13, 2025
- Category
- Impact
Five signs you need a Generator Assessment Program (GAP) inspection
You see a doctor when you notice a health concern.
You see a mechanic when you experience car trouble.
Why should your generator be any different?
When it comes to extending generator life and reducing cost of ownership, early detection is everything.
That’s where EthosEnergy’s GAP inspections come in.
Our three-tiered assessments evaluate your generator’s condition to detect early-stage degradation, before small issues spiral into costly repairs.
Here are five clear signs it’s time to act – and which GAP level your generator may need.
#1 - You haven’t inspected your generator in over a year
When was the last time your generator had a full condition assessment? If it’s over 12 months ago, you could be one minor fault away from unplanned downtime and six-figure repair costs.
Routine inspections are vital – especially when your insurance provider demands them.
Even if they don’t, early indicators like evidence of partial discharge or resistance values can flag deterioration long before it becomes a safety risk.
A GAP 1 inspection includes low-voltage testing, borescope inspection (when accessible), and visual checks – all with no disassembly. Usually completed within just one shift, you’ll be back up and running in no time.
#2 - You’re experiencing operating anomalies
High temperatures? Unexplained vibrations? Partial discharge alarms? These could be early signs of degradation you can’t afford to ignore.
A GAP 2 inspection digs deeper with diagnostics. With the end shield removed, technicians can perform corona camera analysis, Doble testing, and check stator windings for signs of contamination, looseness, or oil tracking.
Typically completed in two to three days, GAP 2 inspections uncover issues that standard testing can’t detect.
#3 - You’re planning a major turbine outage
If you’re already scheduling turbine maintenance, it’s the ideal time for a GAP 3 inspection to minimize disruption.
GAP 3 includes rotor removal, wedge tightness tests, core loss testing, and in-depth insulation diagnostics to gain the clearest picture of your generator’s health.
It’s also where we uncover most root issues, often leading to stator or rotor rewinds that extend operating life by up to 20 years.
#4 – Your generator is older or has unknown maintenance history
Last record of maintenance gone missing? Been over five years since your last full inspection? You’re operating blind.
GAP 3 inspections are essential for aging assets, especially air-cooled units prone to oil leakage and contamination.
Minor issues like oil leaks, loose ties, or insulation deterioration can evolve into major failures if left unchecked. Detecting this wear and tear hiding below the surface helps avoid catastrophic failures with simple fixes.
#5 – You want to avoid emergency repair costs
One in nine GAP inspections uncovers a major issue – like thermal degradation or shorted turns – resulting in rewinds or high-speed balance work. Catching it during a planned inspection can turn a $400K emergency repair into a $25K scheduled intervention.
Your GAP checklist
Whether you’re aiming for peak reliability or looking to stay ahead of expensive downtime, GAP inspections are your generator’s safety net – and your bottom line’s best friend.
Ready to book your GAP inspection ASAP? Get in touch with the generator maintenance experts at EthosEnergy today.