Current Injection Testing in Electrical Systems
Page 1: Introduction
1.1 Purpose of Current Injection Testing
Current injection testing is a critical method used to verify the operation
and coordination of protective relays, circuit breakers, and other
protective devices in electrical power systems. This process ensures the
system will react appropriately during fault conditions, preventing
damage and ensuring safety.
1.2 Overview of Techniques
Current injection is broadly categorized into:
Primary current injection – high current directly injected into the
primary side of current transformers (CTs), simulating actual
operating conditions.
Secondary current injection – lower currents injected into the
secondary side of CTs or directly into the relay circuits, focusing
on logic verification rather than full-system integrity.
Page 2: Primary Current Injection
2.1 Principle and Application
In primary injection, a test set generates a high current (up to several
kA) to be injected into the main busbar or breaker input. This test
simulates real-world fault currents, validating the entire protection chain:
CTs, relays, trip circuits, and breakers.
2.2 Equipment Required
High-current injector (usually transformer-based or solid-state
controlled)
Current clamps or CTs for measurement
Voltage measurement tools for timing and relay operation
2.3 Typical Use Cases
Testing overcurrent protection settings in LV and MV breakers
Verifying CT ratios and polarity
Functional testing of protective relays and breaker trip units
Page 3: Secondary Current Injection
3.1 Concept and Scope
Secondary injection focuses on the relay alone. A known signal is fed
into the relay input terminals to test response time, logic, and trip signals
without stressing power components.
3.2 Equipment Required
Secondary injection test sets (like Omicron CMC or Megger
SMRT)
Communication interface (for modern relays with IEC 61850)
Relay testing software
3.3 Advantages
Easier and safer than primary injection
Can simulate complex fault scenarios
Suitable for logic and communication testing
Page 4: Testing Procedure
4.1 Preparation and Safety
Isolate the test circuit from live components
Verify test equipment calibration
Check for correct wiring and safety interlocks
4.2 Step-by-Step Process
1. Set the desired test current or signal level
2. Gradually increase the output while monitoring relay operation
3. Record the trip time, operating value, and any anomalies
4. Repeat tests for each protection function (e.g., 50/51, 87, 67)
4.3 Documentation
Record test parameters, settings, and results
Compare with relay setting values and protection coordination
studies
Submit results in a standardized format (e.g., FAT or SAT reports)
Page 5: Applications and Conclusion
5.1 Application Areas
Power plants and substations (MV/HV)
Industrial LV panels
Renewable energy integration systems
Grid-interactive inverters and UPS systems
5.2 Conclusion
Current injection testing remains a foundational tool in electrical
protection system validation. While primary injection is vital for system-
wide verification, secondary injection offers speed and precision for
relay-level diagnostics. A thorough understanding and proper
application of these techniques help maintain safe, reliable, and
compliant power systems.
5.3 Recommendations
Use primary injection during commissioning or major retrofits
Use secondary injection for routine maintenance and diagnostics
Ensure personnel are trained in relay testing software and test gear
Combine with thermal scanning and insulation testing for full
system reliability checks
