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Virtual Testing of Protection Systems using Digital Twin Technology

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Virtual Testing of Protection Systems using Digital
Twin Technology
Sughosh Kuber, Mohit Sharma and Andrea Bonetti, Megger
Cédric Harispuru and Amir Soroush, Siemens

Abstract— Recently introduced Digital twin technology is based on

the concept of a virtual device that can mimic an actual physical One of the key elements of digital twin technology is the sharing
device to its greatest degree. Virtual testing of protection systems of data amongst other twins. Digital twin of a relay test
is made possible today using digital twin technology. A digital twin equipment and digital twin of a protective relay can be designed
of a relay would include protection functions, algorithms,
interfaces that can be validated by virtual testing, which would be
in a way that they share the same data through software tools,
equivalent to the testing of the physical relay itself. This would not enabling efficient virtual and physical commissioning tests.
only help engineers verify design and performance of
an individual asset in a substation virtually but would also be able
to validate the complete protection system without being in the
real substation.

Virtual testing includes digital twin of relay test equipment that

performs a virtual injection of voltages and currents to the virtual
analog inputs of the digital twin of the protection relay. The
response is analyzed using the event records created in the relay
or simply using the feedback from the HMI of the relay’s digital
twin. This is referred to as “Open Loop Testing”. Digital twin of a
relay and a test set increases accessibility to a cost effective and
well-rounded training which provides hands-on experience for all
technicians and engineers. With the virtual set-up, costs associated
with rental equipment, and travel could be eliminated.

In this paper, the concept of digital twin technology, virtual

testing of protection systems and the associated benefits are Figure 1 - Twins sharing same data is made possible through the test tools of
relay twins and the test set twins
explained in detail. Virtual validation of protection systems using
digital twin is explored with the help of testing and results.
Specifically, a line distance protection relay is tested virtually B. How does a Digital Twin fit in Power System Protection
using a virtual test system by using the digital twins of protection and Automation?
relay and of the relay test set, as well as physically by using the Digital Twin of a protection relay can allow tests to be done
physical twins of the protection relay and relay test set. The results before or during the erection and installation of a real substation.
are then compared. Additionally, the paper sheds light on possible Settings of a protection relay and schemes can be validated in
advantages of virtual testing towards commissioning and advance without any hardware. Just a web browser access with
maintenance testing of protection systems.
good internet connection is required. The whole device can be
I. INTRODUCTION TO DIGITAL TWIN accessed through the digital copy of the original. Possible errors
in the test configurations, IED logics, or settings can be traced
A. What is a Digital Twin? before the actual site visit for testing and commissioning.
A digital twin is a virtual replica of a product, a machine, a Engineers can even work on the same assets in parallel without
process or of a complete production facility. It contains all the any conflict. Examples of what can be validated are applications
data and simulation models relevant to its original. Digital twins with single or multiple devices, including but not limited to
not only enable products to be conceived, simulated, and protection elements, interlocking, and bay communications.
manufactured faster than in the past, but also to be designed with All these factors lead to time savings and a more precise estimate
a view to improve economy, performance, robustness, or of when the substation will enter service and start contributing
environmental compatibility. From the perspective of relay towards revenue.
testing world, it is a digital functional copy stored in cloud that
includes communication interfaces, protection functions, Moreover, it is also possible to prove the integration of
algorithms, and logics. protection with substation automation system, commonly
known as vertical communication, and substation cybersecurity.
The technology can help substation designers verify substation Protection devices connected via IEC 61850 GOOSE and other
physical design and layout as well as evaluate the performance forms of communication can be simulated and proved as well.
of substation assets individually and as a system.

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With this technology, every stage of the process flow right from normally must be handled on-site are eliminated. Testing can be
the inception of a project to its execution and delivery can be divided into two prime categories – Open Loop and Closed
made more efficient by finding the errors early in the process Loop.
and having them fixed. Engineering services can hop on the
A. Open Loop Testing
project, create it based on customer requirements, implement
settings, perform validation, and show the outcome and results Open loop testing refers to a method of virtual testing where the
to the customers before even taking the charge. Customers can test sequence is performed without monitoring relay’s reaction.
always observe the work online and adjust if necessary. In Instead of waveform generation from physical amplifiers,
cooperation with the client, commissioning coaching and signals are generated in the test software tool and sent digitally
training can also be designed in the commissioning phase. This to the virtual analog and binary inputs of the digital twin of
makes it much easier for employees to start up later. relay. The digital data that was sent from the digital twin of test
The story does not end here. Digital twin technology can be system is stored as a COMTRADE file. COMTRADE files are
extremely valuable during the maintenance phase as well. The predominantly used in the industry and is a widely accepted
ability to test new firmware versions of various IEDs, updates format. These files have also been standardized by IEC 61850
and adjustments to the settings as well as constant optimization for disturbance recorders, thereby making them the perfect
of the substation can prove to be praiseworthy. Due to the real- solution for virtual testing platform. For a COMTRADE file to
time data flowing between the physical asset and its Digital twin, be used in virtual testing, it must be possible to acquire the data
fast and superior technical support on equipment from from the file and process it as if it was real time, but in the
manufacturers can be expected. Local support team can reach virtual time associated with the virtual relay. This means that
out to engineering experts in no time irrespective of their the tests can be faster or slower than real time, but the file
location. Problems at hand can be better explained and root processor needs to interact with the virtual relay so that the
cause investigation of events can be reported back to response time reflects that of the real relay. Once the file is
users/system operators without unnecessary delays. processed, the relay’s response is analyzed using the relay event
data, disturbance recorder, or by simply monitoring the virtual
Digital twin can foresee defects and damage in the relay HMI, depending on the test’s complexity. [1] [3]
manufacturing -machine or system and thus can schedule the
III. TEST SYSTEM
maintenance of the product in advance. By simulating different
scenarios, digital twin provides the best possible solution or In this section, the system under test consideration,
maintenance strategy that makes the maintenance of the protection relay settings, and different functions considered for
product/system much easier. In addition, the constant feedback testing for various types of faults are discussed.
loop between the digital twin and its physical twin can be used
to validate and optimize the system’s process all the time.

Not to forget that remote monitoring and controlling of IEDs and

systems become a necessity in a situation where local access is
limited, like during the COVID-19 pandemic when lockdowns
have been enforced by governments and working remotely or
non-contact is the only viable option.
II. INTRODUCTION TO VIRTUAL TESTING
With the access and availability of digital twins of protection
relays, engineers and technicians can take an extra step to create
an environment and platform to test those digital twins. More Figure 2 - Test System
specifically, test the protective elements, scheme, interlocks,
PLC logics and other necessary algorithms that can impact the The system considered for testing consists of multi-terminal
system in service. It can be possible only with virtual testing. transmission line with length of 100kms. The line is protected
using line protection relays at each end with distance protection
Virtual testing involves process simulation to provide test inputs. as well as POTT configured. The test system is shown in Figure
2. The 1200A line at 220kV phase-to-phase voltage has a
Meaning it provides user the ability of virtual injection of
reactance per length unit of 0.3 Ω/km. The line is protected using
currents and voltages, the virtual energization of the IEDs,
distance protection with 3 quadrilateral characteristic zones.
binary inputs, and transducers for 0 to 20 mA signals. It may Figure 3 shows the detailed relay settings used for the test system.
provide static or dynamic inputs such as a COMTRADE replay.
The design of the digital twin technology permits the output
contacts of IED of the digital twin relay to match with its
physical twin. With this approach, many tests can be prepared
without a secondary injection test set and wiring connections. A
direct benefit is that most of the configuration issues that

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 Figure 3 - Relay Settings - CT, PT and Line Information

The three zones are configured as shown in Figure 4. The line

angle is configured at 85°.

Figure 5 - Relay Settings for Zone Configuration

Figure 4 - Quadrilateral Characteristics

Undervoltage (27) and Overvoltage (59) functions were also
The zone 1 and zone 2 are programmed for forward direction configured in the relay for validation. The settings for those
and zone 3 is programmed for reverse direction. Zone 1 is set to functions are shown in the Figure 6.
protect 80% of the line with no time delay. Zone 2 is set to
protect 150% of the line with a time delay of 400 ms. Zone 3 is
set to protect 133% of the line with a time delay of 1000 ms.
Single line to ground (LN) faults were simulated on various
locations of the line to test the fault locator algorithm.
Permissive overreach transfer trip (POTT) scheme was also
configured for the relays at each end of the line.

Figure 6 - Relay Settings for Voltage Functions

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 IV. TEST SETUP voltage and current signals from digital twin equipment were
In this section, the test setup for virtual testing as well as the mapped to the digital twin relay terminals. Once the mapping
setup for physical relay testing is discussed. was done, the digital twin relay was energized. The tests were
selected one at a time and executed to validate fault locator
A. Digital Twin Test Setup algorithm, distance zone trip times, undervoltage and
The test setup for digital twin platform was performed in two overvoltage trip times, and POTT scheme. Specifically,
phases. The first phase involved creating the relay settings in following tests were created – L1N at 10%, L1N at 20%, L1N
the relay software. The relay settings were exported in the form at 25%, L1N at 50%, L1N at 75%, L1N at 90%, Z1 Timing, Z2
of SIMulation data format (SIM) file from software tool of the Timing, Z3 Timing, 27 Timing, and 59 Timing.
protection relay. This SIM file was then imported to the digital
twin platform to simulate the relay under test. Figure 7 shows the
SIM file after it is imported in the digital twin platform.

Figure 9 - Test files import into digital twin platform

Figure 10 - Signal mapping between digital twin relay and test equipment
Figure 7 - SIM file import in digital twin platform

The second phase involved creating the tests with fault

simulation data using the test software to validate the protection
functions of the digital twin relay. The tests were created in the
form of COMTRADE files as shown in Figure 8 [3]. These files
were then imported into

Figure 11 - Digital twin relay platform with configured tests

B. Physical Relay Test Setup

The test files that were created for virtual testing were re-used
with the physical test set as well. The physical three phase test
equipment (the physical twin of the digital twin relay test set)
was used to run the saved test plan as shown in Figure 13, against
Figure 8 – Example of one test file creation for Virtual Testing the physical protection relay. Analog currents and voltages
were injected to the relay from the test equipment as shown in
the digital twin platform. Once the test files were imported, the Figure 12. Binary equipment on the test equipment as used to
signals were then mapped between the digital twin test monitor the output contact on the relay for operation.
equipment and digital twin relay as shown in Figure 10. The

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 Table 1 - Comparison of operate time and indications given by HMI of digital
twin relay and physical twin relay

shows the comparison of fault locator results from the

Table 2
HMI of digital twin as well as physical twin relays

Test Name Fault Locator from Fault Locator from

Digital twin HMI Physical twin HMI
L1N at 10% 9.9 kms 9.9 kms
L1N at 20% 19.8 kms 19.8 kms
L1N at 25% 24.8 kms 24.8 kms
L1N at 50% 49.6 kms 49.6 kms
Figure 12 - Physical relay test setup L1N at 75% 74.5 kms 74.5 kms
Table 2 - Comparison of fault locator results given by HMI of digital twin
relay and physical twin relays

The trip times for each test was captured from the HMI both
during virtual test as well as physical test. As Table 1 shows,
there is full consistency in the data. This means that no
significant differences have been noticed between virtual
testing and physical testing results. For a deeper investigation
in this comparison, the event records were examined to confirm
the trip times recorded on HMI on both the cases.

Figure 13 - Tests stacked in the test plan mode

Tests performed through virtual testing were repeated for

physical test of the relay as well.
V. RESULTS, COMPARISON & ANALYSIS
A. Comparison of results between DT and RT
Various tests were performed to validate the fault locator,
distance protection zone operation, undervoltage function,
overvoltage function and POTT scheme. These tests were
performed for 5 iterations each both in virtual test setup as well
as physical test setup. The results are compared, and average
Figure 14 - Event Record for L1N at 75% test for Virtual testing
trip times are discussed in the section. Table 1 shows the
comparison of operate times and indications given by HMI of
the digital twin relay and physical twin relay for each test.

Test Name Avg Trip Time in Avg Trip Time in

ms (DT HMI) ms (RT HMI)
L1N at 10% 0.4 1.2
L1N at 20% 0.2 1
L1N at 25% 0.6 1.4
L1N at 50% 0.4 1.8
L1N at 75% 15 13
L1N at 90% No Trip No Trip
Z1 Trip 0 1.2
Z2 Trip 398.4 400
Z3 Trip 996.8 1000
UV Trip 2998 2998
OV Trip 2998.2 2998

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 The results prove that virtual testing, where a digital twin relay
Average Operate Time is tested by means of a digital twin test set, provides test results
consistent with the physical tests, where the physical twin relay
(HMI) - Fault Locator is tested with the physical twin test set, with the consideration
that the twins share the same data (i.e. relay setting files and test
plans as shown in Figure 5 and Figure 13).
14
13
B. Virtual Testing of POTT scheme using Local and Remote
Digital Twins

1.2 1.4 1.8

0.4 1 0.6 0.4
0.2
L1N AT L1N AT L1N AT L1N AT L1N AT
10% 20% 25% 50% 75%

Average Trip Time (DT)

Average Trip Time (RT)

Figure 15 - Average operate time comparison graph for L1N faults at

different locations on the line

It can be noted from Figure 15 that the average operate times for
the tests between virtual and physical tests were within 1 ms Figure 17 - POTT Scheme
difference. Also, average operate times were recorded for the
zone operation trip and plotted as shown in the Figure 16. The Physical test setup to test a communication based scheme could
average operate times difference for the zone operation trip be complicated to arrange due to the requirement of multiple
between virtual and physical tests were 1.2 ms for zone 1, 1.6 test equipments and relays. Trusting the results obtained with
ms for zone 2, and 3.2 ms for zone 3 as seen in Figure 16. virtual testing, a POTT distance protection scheme was
configured and tested in virtual environment. Both local and
remote digital twin relays were simulated in the digital twin test
AVERAGE OPERATE TIME environment at the same time for the virtual POTT scheme test.
The time delay for POTT scheme was set to 60 ms. Test cases
(HMI) - ZONE were generated by the digital twin test set. A single line to
ground fault at 5% on the
OPERATION
Average Trip Time (DT) Average Trip Time (RT)

1000
996.8

400
398.4
1.2
0 Average Trip Time (RT)
Average Trip Time (DT)
Z1 Trip Z2 Trip Z3 Trip

Figure 18 - POTT Test creation from digital twin test set

Figure 16 - Average operate time comparison graph for distance protection
zones line from local relay was simulated for the relay at the left side
of the line (local relay). At the same time, a fault at 95% of the
line was simulated for the relay at the right side of the line
(remote relay). Local relay started in both zone 1 and zone 2,

6
but it operated instantaneously on zone 1 and sent the
permissive carrier to the other line-end. The remote relay
started in zone 2 and tripped for permissive overreach function
in 56 ms., because of the reception of the permissive carrier.

Figure 20 - Setting Errors found during POTT Scheme Virtual Testing

of POTT scheme virtual testing was unsuccessful due to a

setting error. The receive signal mapping in the remote relay
was incorrectly set to active low (off) when the remote input
receives a permissive signal from local relay output.

Figure 19 - Successful POTT trip displayed on the digital twin HMI

Event records were examined to ensure the permissive signal

was received by remote relay to trip for POTT scheme. It could
be a tedious process to procure the physical relays, configure
them and set them up for testing communication based
schemes. Virtual testing definitely has an advantage where the
time taken to create the digital twins of the relays, configuration
and setting them up for POTT scheme test is significantly low.
VI. BENEFITS
Development of digital twin has made the probability of
virtual testing of protection systems very much possible. There
are numerous benefits that could be envisioned with this Figure 21 - Event Record confirming the conventional zone 2 operation
possibility.
Due to the setting error, when L1N fault was simulated at 5%
A. Making Commissioning process time efficient on the line from local relay, the remote relay tripped on zone 2
Given the fact that digital twin is accessible anytime of the day with operation time of 396 ms. The remote zone 2 tripped
and from any location, this not only reduces the wait time instead of the POTT scheme. Event records confirmed that the
between different stages of commissioning job but also, makes receive signal was not received by the remote relay. The
the overall process efficient by pre-validation of protection settings were corrected, and test was performed again which
system even before arriving onsite [2]. The idea of re-using the was successful in the second attempt.
test files that were created using the digital twin of the test set
during virtual testing in real device commissioning makes the
C. Cost Effective and Ease of Training
process easier.
Digital Twin technology reduces the dependency on actual
hardware, be it for a relay or a test equipment. Ease of access
B. Rectify Setting Errors prior to Onsite Commisioning makes virtual testing process cost effective, reducing the time
One of the significant benefits of virtual testing using digital as well as the access to actual relay twin and test equipment
twin is that to be able to validate the relay settings and, in the twin. Training could be provided to large number of engineers
process, find any setting errors that may exist and rectify to and technicians using digital twin relays and test equipment
optimize the settings. This not only saves time prior to onsite instead of renting a fleet of devices for the hands-on training.
commissioning but also ensures that protection settings are Virtual training using digital twin assets will also reduce the
validated thoroughly. One such example of setting errors was travel, shipping, and other associated costs of training [5].
found during the virtual testing for this paper. The first attempt

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VII. CONCLUSION
Emergence of digital twin technology which has made virtual Mohit Sharma is currently part of the engineering team at
testing a possibility, is an opportunity to optimize protection Megger where he designs, develops, and validates testing
systems and associated testing processes. Since digital twin is a solutions in the areas of system protection and automation. He
cloud based technology, it provides easy access virtually to the joined Megger in 2015 as an Applications Engineer for
digital assets. In this paper, distance protection, fault locator protective relay products after receiving his MS in electrical
algorithm and voltage protection were validated in both digital power systems engineering from North Carolina State
twin environment as well as physical test environment. The University, Raleigh. Mohit obtained his B.Tech in electrical
results were compared between virtual testing and physical engineering from the National Institute of Technology, Bhopal,
testing to ensure deviation between the two was not significant India, in 2012. He worked with Indiabulls Power, an IPP, as an
as well as adhered to accuracy tolerance for each of those tests. Electrical Maintenance Engineer responsible for the testing and
POTT scheme was validated using local and remote digital twin maintenance of LV and MV switchgear. He is currently a
relays successfully. During the process of POTT scheme member of IEEE-PSRC.
validation, setting errors were found and corrected prior to re-
testing of the scheme. Tests created in the virtual environment Amir Soroush received his B.Eng degree in electrical
was re-used for the physical testing as well making the test engineering from Iran University of Science and Technology.
process efficient. In this paper, open loop testing was performed He started his professional experience with ABB in 2000 as
in both test environments successfully. Various advantages of design Engineer for power utility Protection and Control system
this kind of testing includes time efficient testing process, find in Iran and has been involved with the commissioning, control,
setting errors, and help with troubleshooting, cost effective and protection, monitoring and automation of power system
ease of training. apparatus up to 400 kV for 20 years. His research interests
include power system protection, IEC61850 , Digital Substation
VIII. REFERENCES and SCADA. In 2020 he joined SIEMENS USA as an
[1] A. Bonetti, C. Harispuru, M. Pitzer, M. Pustejovsky, N. Wetterstrand and application engineer where he is responsible for the application
S. Kachelrieß, "Digital twin technology for virtual testing of power and design of protective relays and Substation Automation
system relay protection," 2021 3rd IEEE Global Power, Energy and
Communication Conference (GPECOM), 2021, pp. 154-160, doi:
Systems.
10.1109/GPECOM52585.2021.9587869.
[2] C. Harispuru and S. Roesler, ‘Virtual Testing with a Digital Twin of
protection devices in the cloud’, presented at the PAC World Americas Andrea Bonetti received his MS in electrotechnical
2019, Aug 2019 engineering from Sapienza University in Rome, Italy. He
[3] A. Bonetti, C. Harispuru, M. Pitzer, and N. Wetterstrand, ‘Virtual testing worked for 18 years in ABB Vasteras, Sweden as HV Power
of protection relays is real!’ – Electrical Tester Magazine – Issue 3
System Protection Specialist. He worked for 5 years as
[4] Siemens Siprotec 5 - User Manual
consultant in power system protection and IEC61850
[5] Raqeeb, Abdul, Andrea Bonetti, Andreas Carlsson, Cédric Harispuru,
Mark Pustejovsky, and Niclas Wetterstrand. FUNCTIONAL DIGITAL applications. He worked as product manager for 7 years and is
TWINS OF RELAY PROTECTION AND RELAY TEST EQUIPMENT presently with Megger Sweden as Senior Application Specialist
ENABLING BENEFITS IN TRAINING AND REMOTE SUPPORT, Relay Protection and IEC61850. He holds a patent in the area
2022.
of IEC 61850 testing tools and algorithms. He is a member of
IX. BIOGRAPHIES the IEC TC 95/MT4 and TC 95/WG 2, IEC committees for
standardization of protection functions and IEC 61850
Sughosh Kuber is a Relay & Protection Applications Engineer application for protection. He has received the IEC 1906 award
at Megger North America, where he provides technical support in 2013. He is guest lecturer at KTH (Royal Institute of
to service companies and utilities responsible for reliable Technology, Stockholm) for IEC 61850 for substation
operation of electrical networks. Sughosh brings over 10 years automation applications since 2008. He is teacher for IEC
of field experience and academic research in power systems 61850 for protection and control applications for the private
from protection schemes and testing to data analysis for energy Swedish University Lernia (Yrkeshogskola).
efficiency and sustainability. Sughosh received his MS in
Electrical Engineering from New Mexico State University. Cédric Harispuru graduated from Centrale Supelec and the
Sughosh earned his B.E in instrumentation technology from University of Darmstadt. Cedric joined Siemens AG in 2006.
J.S.S Academy of Technical Education in Visvesvaraya He is product lifecycle manager and senior key expert for
Technological University. He worked at Sentinel Power engineering tools in the energy automation. He is responsible
Services as Project Engineer from 2013 to 2018 before joining for SIPROTEC Digital Twin, SIPROTEC tools and IEC 61850
Megger. He is currently a member of IEEE-PSRC. engineering. He is a member of IEC TC57 WG10.