Top 5 Mistakes to Avoid in Substation Testing

Testing and commissioning (T&C) of high-voltage substations is a critical step in ensuring safety, reliability, and compliance. However, mistakes are common, and avoiding them can save time, cost, and potential hazards.

1. Skipping Detailed Test Planning

Many teams jump straight into field testing without reviewing the schematics, protection schemes, or relay settings.

✅ Solution: Prepare a comprehensive test plan, including sequence, objectives, responsibilities, and required instruments.

2. Improper Equipment Calibration

Using uncalibrated or outdated instruments can give incorrect readings, leading to miscoordination and unreliable results.

✅ Solution: Ensure all test equipment is calibrated and certified before starting.

3. Neglecting Safety Protocols

High-voltage testing can be hazardous. Skipping PPE or lockout/tagout procedures puts both personnel and assets at risk.

✅ Solution: Follow strict safety procedures, including grounding, PPE usage, signage, and clearance protocols.

4. Poor Documentation

Incomplete or inaccurate test reports can create regulatory issues, warranty disputes, or future maintenance challenges.

✅ Solution: Document every test with pass/fail results, observations, and corrective actions in an organized format.

5. Ignoring Coordination Studies

Incorrect relay coordination can cause unnecessary outages, false trips, or equipment damage.

✅ Solution: Conduct thorough coordination studies, simulate fault scenarios, and verify relay settings before energization.

Conclusion

By avoiding these common mistakes, utilities and EPC contractors can ensure smooth commissioning, enhanced system reliability, and safer operations. Substation testing is not just about checking boxes—it’s about building a foundation for long-term performance.