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Construction / Installation

Orion Rail Construction Services offer an extensive range of electrical services covering all aspects of rail and substation construction and installation. Ranging from cable pulling and relay works through to earthing and the provision of high voltage ring-main systems .

All necessary Testing and Commissioning is undertaken prior to energisation.

We also compliment this with an extensive range of civil services, including construction and excavation enabling us to provide clients with a comprehensive package.

We also provide a refubishment service covering the replacement of rails, sleepers, ballast, fencing & retaining walls. Along with the installation of Lightning Protection to BS 6651.


Orion Rail Construction Services offer an emergency Call Out service operating 365 day a year 24 hour a day.

We provide both Civil and Electrical maintenance services ensuring we have the correct knowledge and equipment to assist with your projects.

The Orion Rail Construction Services team have extensive experience in structural inspection and repair, track examination and reconditioning, drainage works, replacement of timbers, sleepers and railings and corridor presentation.  Along with a graffiti removal and de-vegetation service.

With many potential causes for buried cables to fail, Orion Rail Construction Services can provide a cable fault location service that includes:

Taking full control of electrical safety, pinpointing the position of the fault and excavating to gain access to the faulty cable. Repairing and testing of the cable prior to its return to service along with the reinstatement of the groundwork.

Responsibly dispose of existing electrical assets in accordance with environmental legislation.


Orion Rail Construction Services provide a regular substation inspection service in addition to assessment inspections. Ensuring all key parts are inspected and recorded on a report sheet, which is designed to meet manufacturers’ recommendations for electrical maintenance inspections in accordance with BS 6626.

A routine inspection would consist of inspecting the tripping batteries and charger, a visual inspection of all existing substation equipment, taking transformer insulating oil samples and performing tests, the replacement of transformer desiccants if present and checking the building security.

Routine inspections are a valuable method of highlighting potential problems and current asset condition.

Hazardous Area Inspection:  We carry out visual, close and detailed inspection of hazardous area equipment.

Testing and Commissioning

Orion Rail Construction Services offer a full Testing and Commissioning service along with a range of other testing services, these include:

  • Cable Fault Location testing
  • Pressure Testing equipment and cables, both using A.C. and D.C. test sets.
  • Primary and secondary Protection Testing
  • Earth Installation Testing – in accordance with BS 7430 (without disconnection)
  • Power Factor Correction Equipment Testing and installation
  • See our full summary of services below.

Summary of services

Construction, Installation, testing & commissioning and maintenance of substations, switch boards and associated switchgear including:

  • HV Cable jointing
  • LV Cable jointing
  • Switchgear installation
  • Transformer installation
  • Grid TX Installation
  • Cable Pulling
  • Cable Containment
  • Excavation
  • Plant Movements
  • Temporary Supplies
  • Control Wiring
  • Project Management
  • Project Specification
  • Project Commercial
  • Regulated Networks
  • PV Cell Generation
  • CHP Generation
  • Commissioning

Operational Management Services including:

  • Cable Fault Location
  • Testing
  • Stand-by Cable
  • Spiking Cable
  • Partial Discharge Testing
  • VLF (Very Low Frequency) pressure testing
  • Power quality analysis
  • System analysis
  • Safe systems of Work

Low Voltage Maintenance includes:

  • Protection Testing
  • LV Switchboards
  • Distribution Boards
  • Temporary Supplies
  • Generation
  • Standby Generators
  • Power Factor Correction
  • Riser Closets
  • Feeder Pillars
  • Surge Arrestors
  • G 59 Testing
  • Motor Starters
  • Uninterruptible Power Supply Maintenance
  • Small wire testing
  • PV Cell Systems
  • CHP units
  • Metering
  • Condition monitoring
  • ACB Maintenance
  • MCCB Maintenance

High Voltage Maintenance up to and inclusive of 11kV includes:

  • Oil Switchgear
  • Vacuum Switchgear
  • SF6 Switchgear
  • G59 Testing
  • Air Switchgear
  • Protection Testing
  • Sweep Frequency Response Analysis Transformer Testing
  • Breaker Timing Tests
  • Oil Analysis
  • Resin Tx Maintenance
  • Busbar inspections
  • Cable End-box Inspections
  • HV Capacitors
  • Condition Monitoring
  • Motor Starters
  • Generation
  • Standby Generators
  • Temporary Supplies
  • CHP units
  • Metering

High Voltage Maintenance for 33kV and above includes:

  • Visual Inspection
  • Close Inspection
  • Detailed Inspection
  • Lighting System Testing
  • SF6 Testing
  • Inspection & Testing
  • Oil Switchgear
  • Vacuum Switchgear
  • SF6 Switchgear
  • Air Switchgear
  • Oil Transformers
  • On-Load Tap Changer
  • Protection
  • Pressure Air Systems
  • Generation
  • Hazardous Area Inspection

Asset Management Services including:

  • Partial discharge testing
  • COMA
  • Asset assessment
  • Dilapidation studies
  • Sweep Frequency Response Analysis
  • SOP / NeDER Evaluation
  • Thermographic survey
  • Dissolved Gas Analysis