Home » Case studies » Case Study: Software Engineering for a Compact Medium-Voltage Protection Relay

Software for a Medium-Voltage Protection Relay – Case Study

This case study explores the digital transformation of the energy sector, focusing on how TTMS optimized processes and increased efficiency for a global leader in energy management and automation. The goal was to develop a scalable and flexible application that consolidated multiple systems, leading to improved operational efficiency, cost savings, and long-term technological support for the client.

Energy

Case Study: Software Engineering for a Compact Medium-Voltage Protection Relay

Designing software for compact medium-voltage protection relays requires precise code optimization while maintaining full protection functionality. Discover how the TTMS engineering team developed advanced firmware and intuitive configuration tools, ensuring reliable distribution network protection and full interoperability based on the IEC 61850 standard.

Design Challenges: Software for Compact MV Protection Relays

A manufacturer of power engineering equipment approached us with the need to develop software for a compact medium-voltage (MV) protection relay. The device was intended to protect feeders, motors, transformers, and generators in MV distribution networks, offering a wide range of protection functions in a compact, intuitive form factor.

Protection Software Architecture and Key Functionalities

The software engineering team was deeply involved in the project from its earliest stages. The scope of work included:

communication integration,
development of a configuration tool for field technicians.

As part of the project, the following components were delivered:

implementation of real-time protection logic (e.g. 50/51, 67, 87),
event recording, disturbance logging, and HMI/LED panel handling,
integration of communication stacks: IEC 61850 (MMS/GOOSE), Modbus, DNP3, IEC 60870-5-103/104, Ethernet/IP,
development of a modern relay configuration and management application in C#/.NET with an intuitive graphical user interface.

Would you like a similar project? Contact us

Technology Stack: Embedded Software Standards and Tools

To ensure real-time reliability and compliance with rigorous energy standards, we based the system architecture on a proven technology stack dedicated to embedded solutions.

Firmware: C/C++ and assembly on an embedded platform with a microprocessor or DSP
Communication: protocols compliant with IEC 61850 Edition 1 and 2
PC Application: Microsoft .NET, most likely using WPF
Testing: test sets (Omicron, Doble), unit and integration testing, static code analysis, CI/CD pipelines, Git
Standards: compliance with IEC 60255

This carefully selected toolset enabled the creation of efficient and secure code, ready for certification according to international IEC standards.

Would you like a similar project? Contact us

Relay Integration with Power Systems and SCADA

A key design requirement was full relay interoperability across diverse network environments – from modern digital substations to legacy installations requiring support for older protocols.

Support for both modern and legacy SCADA/DCS systems (IEC 61850, DNP3, Modbus TCP/RTU, IEC 60870-5-103/104, SPAbus)
Cooperation with arc flash sensors and low-power instrument transformers (LPCT/LPVT)
Transmission of measurement data and event records to supervisory monitoring and energy management systems

Thanks to extensive communication capabilities, the device can serve as an intelligent node in Smart Grid networks, integrating data from multiple sources.

Optimizing Performance and Security in Protection Systems

Packing advanced protection logic into a compact device required overcoming a series of technical barriers, mainly related to resource optimization and user ergonomics.

Broad functionality in a compact device: code optimization and use of hardware acceleration
Multiple communication protocols: implementation of a communication middleware layer
Ease of use: intuitive user interface with settings divided into “standard” and “advanced” modes
Legacy functionality integration: compatibility with earlier devices and protocols
Quality and certification: stability testing, in-house supervision, rapid security fixes

The engineering approach applied allowed us to strike a balance between rich functionality and ease of use, which is critical for field technicians.

Project Results: Reliable Protection for Distribution Networks

The deployment of the new software not only modernized the client’s product offering but also delivered tangible business benefits, strengthening their leadership position in the medium-voltage (MV) automation segment.

Product enhancement: improved usability combined with advanced protection features
Market impact: wide adoption by industrial and utility customers
Innovation: arc flash protection and support for LPCT/LPVT
Continuous improvement: regular firmware and tool updates
Customer value: interoperability, scalability, and long-term support
Long-term partnership: recognition of the team as a trusted development partner

The success of this project laid the foundation for a continued, long-term R&D partnership in developing future generations of intelligent protection devices.

Need support in embedded software development for the energy sector? Explore our Energy capabilities and get in touch with us