"Our older substations were physically designed as double bus-single break with breaker bypass switches. The bus tie was used for both bypassing a breaker for planned maintenance and as a permanent spare since OCBs took quite a while to replace. Reconfiguring the bus tie and bus differential protection was a very big pain, so the stations were typically operated as a main & transfer scheme."
Sounds like each breaker had access to both buses via two disconnects? Did one relay or two relays give bus differential protection and what kind was used? Modern relays like SEL can easily be configured to accept dynamic current differential provided the disconnects have position switches where the relay has automatic awareness of the each disconnect's position knowing whether to add or subtract CT inputs from each dynamic buss zone. Although that is not to say I am not in the same boat as you lol. Most older substations have their existing relays with no position switches so substations designed as single breaker, double buss are often deliberately run as main and transfer with relays configured accounting for only one bus zone. As such a stuck breaker is a far greater concern since all circuits have to be cleared. Of course it is often justified with the reason being that a single relay summing both zones, or a typical application with older relays, is more likely to nuisance trip clearing both buses from service switching error (which is more likely to happen on a dynamic system) or the failure of a single relay will trip both buses as is, like this for example:
As for the buss coupler (or more precisely transfer bus breaker) what made re-configuring difficult? My practice is to omit differential bus protection altogether for the transfer buss and have the transfer breaker protect it. When not giving protection in place of another breaker I simply set a very low instantaneous current pickup (50P, 50G) to indicate that the transfer buss has faulted.
"With the reduced maintenance of SF6 breakers, we now just open a bay for short duration of the maintenance. We have both a spare SF6 breaker and a mobile SF6 breaker that are available for emergency replacements with a few 10s of hours. With the higher circuit availability, we dedicated each terminal to a specific bus and installed much simpler sets of bus differential relaying."
I thought about doing that many times (dedicating each circuit with two separate independent buss relays), but in your case what is the scenario for a bus fault? Do you keep half the circuits out until the bus is repaired or can you transfer the now de-energized circuits into the remaining buss while repairs are being made? With one buss zone while the entire station clears, all of the buss one disconnects can be opened and then all the buss two disconnects closed (often via SCADA) bring all circuit online rapidly while bus one is repaired. After repair, to transfer back all bus one disconnects are closed and then after, all bus two disconnects are opened. This is easily done without worry since only one buss zone is involved.
"In our latest ring bus station, we made the design choice to allow both generation sources to be adjacent instead of alternating gen/load/gen/load. Having breaker failure while one PCB was already open seemed a lower risk than having lines cross each other outside the station reach the alternate location."
PCB= power circuit breaker? Eliminating line crossing within a substation or other lines is a good goal both for safety and reliability. I tend to cringe when I see lines going over bays or multiple circuits to get to the other side. Ive seen cases where serve ice storms caused insulators to break with one circuit taking out two others.
"Although ring bus/breaker and a half schemes are often touted as allowing maintenance of any component while maintaining service to all terminals, it really just allows for the CB mechanism maintenance. We have had a number of inadvertent trips while testing CTs and/or relays connected to one in service PBC and one out of service PCB."
PBC? Sorry, Im not good with acronyms lol. Is it the middle breaker that trips open? Im just having a hard time grasping this. Then again breaker and a half is a design a least deal with it.