Testing and commissioning services
Protection Relay Testing Services Australia
Talk to an engineer: 1300 730 499 or service@megavar.com.au
Specialist Protection Relay Testing and Scheme Validation Across Australia
Protection systems are the last line of defence for high-voltage assets and the people who work near them. A single misconfigured relay or untested protection scheme can result in catastrophic equipment failure, uncontrolled fault energy, and serious safety incidents. Megavar provides specialist protection relay testing services for substations, renewable energy projects, industrial HV systems, and transmission networks across Australia.
Our engineers use Omicron secondary injection test equipment to verify every relay setting, trip time, scheme logic sequence, and communication path – giving asset owners absolute confidence that their protection systems will operate correctly when called upon.
Scope and deliverables
What you get, and what we need from you
We test protection as a standalone package, or as part of a wider testing and commissioning scope that includes primary plant, SCADA and energisation.
We do
Test plan, secondary and primary injection, scheme and functional tests, settings checks against the approved issue, and close-out.
You provide
Approved settings and drawings, site access, switching and isolation agreed with your authorised operator, and witnessing where your process needs it.
You receive
Results files, a test report and as-left settings files. Where the network owner requires it, settings uploaded to its settings database (for example TasNetworks StationWare).
Scope still forming?
Send what you have. We price staged outages, return visits and items still to be confirmed as separate lines.
Protection Functions We Test
- Overcurrent (50/51, 50N/51N) – Phase and earth fault overcurrent elements, inverse-time and definite-time characteristics, pickup levels, and operating times.
- Differential (87T, 87B, 87L) – Transformer, busbar, and line differential. Stability testing under through-fault, CT ratio/phase compensation, and harmonic restraint validation.
- Distance (21/21N) – Zone reach testing (Z1–Z4), directional verification, power swing blocking, weak infeed, and permissive scheme logic.
- Under/over voltage and frequency (27/59, 81O/81U) – Pickup levels, time delays, and anti-islanding integration for generators and BESS.
- Breaker failure (50BF) – Timer verification, retrip logic, and backup trip initiation.
- Auto-reclose (79) – Dead time, reclaim time, shot counting, and lockout logic.
- Arc flash detection (ARCF) – Light sensor verification, trip time, and zone discrimination.
- Synchrocheck (25) – Voltage, frequency, and phase angle matching for CB closing.
Testing Methodology
Secondary Injection Testing
Using Omicron CMC 356 and CMC 500 test sets, we inject precise current and voltage signals into relay measurement inputs to simulate fault conditions. This verifies pickup settings, operating times, directional elements, and trip outputs without disturbing the primary power system. Results are recorded in Omicron Test Universe software and compared against approved protection settings, manufacturer specifications, and relevant standards (AS/NZS 60255, IEC 60255, IEEE C37 series).
Primary Injection Testing
For end-to-end verification, we use the Omicron CPC 100 to inject current through the CT primary. This confirms the complete protection loop: CT ratios, polarities, wiring integrity, and trip circuit supervision.
Scheme Logic and Functional Testing
Beyond individual relays, we verify complete scheme logic: IEC 61850 GOOSE messaging, hardwired intertripping, permissive signalling, busbar zone selection, breaker-and-a-half configurations, and SCADA alarm/event integration. Every operational scenario is tested – normal operation, fault conditions, CT/VT supervision failures, and relay self-monitoring alarms.
Relay Manufacturers We Support
Our engineers hold current competency across all major platforms: ABB REL670, REF615, RED670, RET670; Siemens SIPROTEC 4/5 (7SJ, 7SA, 7SD, 7UT, 7SS); SEL-311, 387, 421, 451, 751; GE Multilin (T60, D60, L90, B90, C60); Schneider Electric MiCOM P12x–P84x; and legacy electromechanical relays (CDG, KCGG, MCGG).
Case study: 30 × Siemens 7SJ82 relays tested and commissioned at Chapel Street
Applications
We provide relay testing for new HV substation commissioning (greenfield and brownfield), routine maintenance programmes, post-fault investigation, protection settings changes and firmware upgrades, renewable grid connections (solar, wind, BESS), industrial HV switchboard commissioning, and mining sector electrical infrastructure.
Tested to the standards your network specifies
- IEC 60255
- IEEE C37
- IEC 61850
Plus client network standards and OEM commissioning requirements.
Project
Chapel Street Substation
- Feeder, incomer, bus coupler and bus zone protection on 30 relays
- Stability testing on transformers T5 and T6
- As-commissioned settings uploaded to StationWare at handover
Take it to your team
Capability statement
High-Voltage Testing, Commissioning and Maintenance Services
Primary plant testing, protection and SCADA commissioning, substation maintenance and the design capability behind them.
Clients
What our clients say
Megavar are industry leaders in HV commissioning services, offering high quality commissioning services. They are experts in high voltage commissioning services, and their work is always on time, on budget and to the highest quality.
Megavar has repeatedly demonstrated their ability to quickly mobilise their highly skilled technicians to meet project demands and effectively develop solutions in a highly proficient and professional manner.
Megavar have been a pleasure to deal with, and we look forward to continuing to work closely on future projects for years to come.
FAQ
Frequently Asked Questions Protection Relay Testing Services Australia
What is secondary injection testing?
Secondary injection uses specialised equipment (Omicron CMC 356) to inject precise current and voltage signals directly into a protection relay’s inputs, simulating fault conditions. This verifies correct operation at approved settings and within required time. It is the standard method for commissioning and maintenance testing of protection relays.
What is the difference between primary and secondary injection?
Secondary injection tests the relay in isolation by injecting at relay terminals. Primary injection injects through the CT primary winding, testing the entire loop from CT through wiring to relay and trip coil. Primary injection is used for end-to-end verification during new installation commissioning.
How often should protection relays be tested?
Modern numerical relays with self-monitoring typically require testing every 4–6 years. Electromechanical relays need testing every 1–2 years. All relays should be tested after settings changes, firmware upgrades, or protection operations during a fault.
Does Megavar test IEC 61850 GOOSE-based protection schemes?
Yes. Our engineers test IEC 61850 GOOSE communication for peer-to-peer signalling including busbar protection zone selection, intertripping, and breaker failure initiation, using Omicron equipment with IEC 61850 capability.
What relay manufacturers does Megavar support?
We test relays from ABB, Siemens, SEL, GE Multilin, Schneider Electric (MiCOM), and legacy electromechanical relays. Our engineers maintain current competency across all platforms through ongoing training and field experience.
Can Megavar provide relay testing anywhere in Australia?
Yes. We deploy nationally from offices in Tasmania, South Australia, New South Wales and Queensland, covering every state and territory.
ISO Certified and Licensed in Every State
Megavar is certified to ISO 9001 (quality), ISO 14001 (environment) and ISO 45001 (safety), and holds electrical contractors licences in every Australian state.
Ready to book your protection relay testing? Contact Megavar today on 1300 730 499 or visit our contact page to request a quote. To see what the testing involves first, read our protection relay testing guide.
Request a quote
Tell us about the job
An engineer replies by the end of the next business day (Monday to Friday, 8:30 am to 5:00 pm). Scope still forming? Send what you have. Outage or urgent fault? Call to discuss the site, access window and mobilisation.
Talk to us now
1300 730 499 service@megavar.com.au Hobart · Launceston · Adelaide · Newcastle · GladstoneExplore Our other services
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Testing guides
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