Protection Relay Testing Services Australia
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.
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 256plus 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 and CP CU1 coupling unit 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).
Applications
We provide relay testing for new 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.
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 the ACT, covering every state and territory.
Ready to commission your substation? Contact Megavar today on 1300 730 499 or visit our contact page to request a quote.
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We’re incredibly excited to share a big milestone in Megavar’s story—we’ve officially opened our new Newcastle branch, located at 22 Gavey Street, Mayfield,
