Bushing Refurbishment vs. Replacement: What Utilities Need to Know
When high-voltage bushings show signs of wear or failure, utilities are often faced with a critical decision: refurbish or replace? While replacement may seem like the default option, refurbishment can deliver significant cost savings, faster turnaround, and long-term reliability—without compromising performance.
In this post, we’ll explore the key factors utilities and OEMs should consider when evaluating bushing refurbishment vs. full replacement. We’ll also highlight sustainability and supply chain advantages, and explain how to identify viable candidates for refurbishment.
The Role of Bushings in Grid Reliability
Bushings are high-voltage dielectric components that allow conductors to pass safely through grounded barriers—such as transformer tanks, circuit breakers, and switchgear housings. They are essential to the insulation and mechanical stability of electrical equipment.
Over time, bushings can degrade due to:
Thermal cycling
Mechanical stress
Electrical loading
Environmental exposure
Failure can lead to flashover, unplanned outages, or equipment damage—making proactive inspection and maintenance essential.
Refurbishment vs. Replacement: What's the Difference?
Replacement involves sourcing a completely new bushing assembly—often from an OEM or international supplier.
Refurbishment restores the existing bushing to near-new condition using new dielectric and mechanical components, often reusing the core housing or flange when structurally sound.
At PBI, our refurbishment process includes:
Complete disassembly and inspection
Replacement of worn or degraded dielectric components
New gaskets, hardware, and bushings fabricated from our RIP process
Full mechanical and dielectric testing to the highest standard in the industry
The result: a bushing that meets or exceeds original performance specs—delivered in a fraction of the time and at a fraction of the cost.
Cost-Benefit Breakdown
Bottom line: Refurbishment delivers rapid ROI, especially when paired with high-performance materials like Polykeram that extend service life.
Sustainability Advantages
In a sector increasingly focused on sustainability, refurbishment aligns with key environmental and operational goals:
Reduced landfill waste: Reusing metal housings and hardware avoids scrapping structurally sound components.
Lower carbon footprint: Domestic refurbishment avoids the emissions associated with overseas manufacturing and shipping.
Extended asset life: Keeps existing equipment in service longer—reducing capital expenditure and resource consumption.
Utilities and co-ops aiming to meet ESG targets are finding that refurbishment is a smart, low-impact alternative to full replacement.
When Is a Bushing a Good Candidate for Refurbishment?
Not every bushing is suitable for refurbishment, but many are. Ideal candidates typically meet the following criteria:
Structurally sound housing: No severe mechanical damage or corrosion.
Low moisture ingress: No evidence of internal dielectric breakdown or contamination.
Known part specifications: Access to original drawings or measurements ensures accurate remanufacturing.
At PBI, we evaluate each bushing to determine viability. Our engineers use a combination of visual inspection, dimensional analysis, and testing to confirm whether refurbishment is the right option.
Industry Trends Driving Refurbishment Demand
Several current trends are making refurbishment more attractive—and more necessary—for today’s utilities:
Supply Chain Disruption
Global shortages and long lead times have made OEM parts difficult to source. Refurbishment offers a domestic, tariff-free solution that can bypass these delays entirely.
Cost Control
With tighter budgets and regulatory scrutiny, utilities are seeking smarter ways to maintain reliability without overspending on capital assets.
Legacy System Support
Many older substations and breaker types are no longer supported by OEMs. Refurbishment enables continued operation without requiring full system replacement or redesign.
Grid Hardening Initiatives
As utilities work to reinforce the grid against extreme weather, refurbishment offers a quick, cost-effective way to upgrade aging infrastructure.
Why Utilities Trust PBI for Refurbished Bushings
PBI has been a leader in dielectric component manufacturing for decades. Our refurbishment services offer:
Fast lead times, backed by domestic production and in-house tooling
Rigorous quality control and final testing for peace of mind
Custom-fit replacements for legacy systems, including drop-in compatibility with OEM units
Every bushing is rebuilt to meet the demands of today’s electrical grid—without the delays, costs, or risk of international sourcing.
Refurbishing high-voltage bushings is no longer just a stopgap—it’s a strategic solution for utilities and OEMs looking to cut costs, reduce waste, and strengthen reliability. When done right, refurbishment delivers long-term performance at a fraction of the cost and lead time of replacement.
PBI’s expertise in custom dielectric engineering and U.S.-based refurbishment makes us a trusted partner for utilities navigating today’s operational and supply chain challenges.