Protection Relay Testing

Protection Relay Testing

Programming and secondary injection testing of protection relays is a service offered both for onsite, and in the factory.

Protection relay testing is a crucial process in the field of electrical engineering and power systems. Protection relays are devices designed to monitor the electrical parameters of a power system and take action to protect equipment and personnel in the event of electrical faults or abnormal conditions. Testing these relays ensures they function correctly when needed.

Testing & Commissioning

Why our Protection Relay Testing?

AS/NZS 61439 Compliant
Our Protection Relay Testing services are compliant with AS/NZS 61439. We have verified various designs at both PLUS ES in Lane Cove and TUV in Heidleberg.
Thousands of Switchboards Tested
Our Protection Relay Testing team has extensive experience and has worked on thousands of projects across Australia.
Trusted by Industry
With extensive experience, comes reliability. We are trusted by many major organisations across Australia as a safe pair of hands for their switchboard manufacturing requirements.
Electrical Switchboards manufacturer MSB distribution boards Medium voltage, 11kv 22kv 33kv control panel

Testing these relays ensures they function correctly when needed.


Protection relay testing is essential for ensuring the reliable and safe operation of power systems. Regular testing and maintenance of protection relays help prevent electrical faults from escalating into major incidents, minimising downtime and protecting both equipment and personnel.

Here are the key aspects of protection relay testing:

1. Purpose

The primary purpose of protection relay testing is to verify that the protection relays are working as intended and will respond appropriately to fault conditions, thereby preventing damage to electrical equipment and ensuring the safety of the power system.

2. Types of relays

Protection relays come in various types, each designed to monitor specific electrical parameters or respond to certain fault conditions. Common types include overcurrent relays, distance relays, differential relays, and more. Testing procedures may vary based on the type of relay.

3. Preparatory Steps:



Before testing, gather documentation, including relay settings, drawings, and manuals.


Implement safety measures to protect personnel and equipment during testing, especially when dealing with high voltage systems.


4. Functional Testing

This involves simulating fault conditions or abnormal situations to verify that the protection relay responds correctly. Functional testing checks if the relay operates within its specified time and coordination with other relays.

5. Calibration

Ensure that the relay’s settings, such as current and voltage settings, match the requirements of the power system. Adjust settings if necessary.

6. Secondary Injection Testing

Secondary injection testing is a common method for testing protection relays. It involves injecting a test current or voltage into the relay’s secondary circuits to simulate fault conditions. This verifies the relay’s response without disrupting the primary power system.

7. Primary Injection Testing

In some cases, primary injection testing may be necessary, especially for high- current relays. This involves injecting a fault current directly into the primary system to test the relay’s operation.

8. Trip and Alarm Testing

Verify that the relay trips (activates) when a fault is simulated and that alarms are triggered as expected. This ensures that the relay can disconnect faulty equipment and provide alerts.

9. Timing Tests

Timing tests assess the relay’s response time to fault conditions. These tests are critical for coordination with other relays and circuit breakers in the system.

10. Communication Testing

If the relay has communication capabilities, test its communication links, protocols, and data exchange with other devices in the network.

11. Record Keeping

Detailed records of all test results, including settings, test conditions, and relay responses, should be maintained for future reference and compliance with regulatory requirements.

12. Reporting

 After testing is complete, generate a comprehensive test report summarising the results, any issues encountered, and any recommended actions, such as relay adjustments or replacements.

Electrical Switchboards manufacturer MSB distribution boards Medium voltage, 11kv 22kv 33kv control panel

What Our Clients Say

This company is excellent. We go to them first for Grid Protection Units. They offer great value especially when you add their top notch customer service. As usual, we needed something STAT this week and the team didn't leave us hanging, even finishing it up and testing on a Saturday to meet our timetable. Graham Dennis shout out.
Mark Horsfall (Simmark)

CTC has always provided great service on the many occasions we have worked with them on our solar projects. They are reliable, responsive, and overall an excellent company.
Daphne from The Greenguys Group

Big fan of these guys - always answer the phone. They helped me out when Endeavour Energy required a neutral voltage displacement protection function on the solar installation
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