Pipeline spheres are spherical pigging devices used to clean, dewater, batch, and separate products inside a pipeline, and as a specialized pipeline spheres manufacturer, Sun Pipeline Solutions builds them for reliable flow control and long service life.
At SUN we are always developing pipeline spheres that meet your pipeline integrity constraints. The sphere solution we have developed is a unique manufacturing process: pouring and making the spheres in one piece compared to two pieces bonded together. This process allows the spheres to be made without a seam, eliminating concern over seam splitting or delaminating. It also permits valve bodies to be firmly embedded in the wall of the sphere to prevent leakage from around the valve, which is a key advantage of our inflatable pipeline spheres. Super Spheres use our MDI polyurethane which is proven for better flexibility, rebound memory, and abrasion resistance across a broad range of chemical and pipeline environments. As a trusted pipeline spheres manufacturer, SUN stands behind every unit: super sphere, serious results.
Variety of Durometers
Solid Configuration
Inflatable Configuration
Pipeline Operators perform regular pig / scraper tool runs in their pipelines to maintain integrity and throughput efficiency in order to safely transport gas and liquid products.
There are various methods to remove debris or contaminants from pipelines. The most used is pushing through the pipeline a pig/scraper tool with the product flow to push debris to a containment facility at the receive station.
One common component of crude oil is paraffin wax that accumulates in the internal diameter of pipelines. The removal requires the use of pig/scrapper tools in a progressive sequence with or without chemical batches.
One of the most effective methods of removing debris from pipeline segments is the designing of product Bypass Flow in pig/scraper tools to flush or jet debris forward as the tools traverse the pipeline segment. There are operating parameters required to incorporate this strategy.
The process of transporting more than one (1) product through a pipeline is called batching. The most effective way to separate batches is with two (2) high sealing pig/scraper tools, one leading and one behind.
This is the process of filling and displacing products in a pipeline is primarily done with high sealing pig/scraper tool(s).
The process to remove a product from a pipeline is called purging. Depending on the type of product, gas or liquid, a high sealing scraper/pig tool is normally used to push the product out of the pipeline.
There are several types of liquid that can accumulate in pipelines or are pumped in due to a process need, such as hydrotesting, that require removal/de-watering. The use of a high sealing pig / scraper tool is the most effective method to pushout the liquid to a containment facility at the receive station.
The lack of proper pig/scraper tool seal during the filling or removal process of a liquid with the use or presence of air or a gas in a pipeline segment can cause the condition commonly known as Airlock. This is the passing or mixing of air/gas into the liquid to the point that the tool is stopped due to the bypass and/or compression of the air/gas in the liquid batch.
When a pipeline segment is hydrostatically tested, the water is first introduced and afterwards removed from the pipeline with a high sealing pig / scraper tool. After the removing of the water, the humidity level is reduced to the required dew point per the pipeline operator specification. This process may require a combination of pig/scraper foam pigs and hot-dry air or nitrogen.
The initial option in detecting a reduction in size of the internal diameter of a pipeline is with a gauging plate mounted on a pig/scraper tool that will traverse the pipeline segment. The effectiveness of a gauging pig is contingent on the Launch / Receive process and Pipeline Operating Conditions.
The use of internal coating in pipelines is an effective method to reduce corrosion and debris buildup in pipelines. The coating is normally applied to the pipe joints prior to the construction of the pipeline segment, however it can be applied in existing pipelines with a process that uses pig/scraper tool (s) designed for this purpose.
An important process in the building of a pipeline segment is maintaining it clean and free of debris during and after construction. This is critical prior to the execution of a hydrostatic operation. The selection and running of cleaning, filling, de-watering, and drying pig/scraper tools is very important to meet the specifications to prepare a pipeline segment for commissioning and operation.
One of the options used by pipeline operators to measure volume and displace products in a pipeline segment is a pig/scraper tool commonly known as Spheres. These are made in different diameters, inflatable or non-inflatable, durometer hardness, and materials. They require Launch and Receive Systems designed for Spheres and/or conventional pig/scraper tools.
Pipeline spheres are used to clean, dewater, batch, and separate products as they travel through a pipeline. Their spherical shape lets them move smoothly through bends and fittings, making them ideal for maintenance runs and for holding back or dividing different products in a line.
Inflatable pipeline spheres are hollow spheres that can be filled with liquid or gas to reach a precise diameter and interference fit. This adjustability lets operators match the sphere to the exact pipe size, improving sealing, batching accuracy, and cleaning performance across varying line conditions.
As a pipeline spheres manufacturer, SUN pours each Super Sphere in one piece rather than bonding two halves together. This seamless process removes the risk of seam splitting or delamination and allows valve bodies to be embedded directly in the sphere wall to prevent leakage.
Our pipeline spheres are made from MDI polyurethane, chosen for its flexibility, rebound memory, and abrasion resistance. This material performs reliably across a broad range of chemical and pipeline environments, extending the working life of each sphere.
Selecting the right sphere depends on pipe diameter, product type, and the task, whether cleaning, dewatering, or batching. Our team helps operators match the correct size and configuration, including inflatable pipeline spheres where an adjustable fit delivers the best seal and performance.