Application Note: Revolutionizing Laboratory Gas Monitoring: A Cost-Effective Solution

February 5, 2024 | Application NoteLife Sciences


A pharmaceutical customer in Pennsylvania required a solution to help monitor toxic, flammable, and O2 depleting gases in their laboratory. They need the ability to change the sensors depending on what gases are being detected at the time; in this case – oxygen (O2) and Silicon Tetrachloride (SiCl4). The detectors they have are permanent, meaning that once they install the unit, they have to replace the entire thing to sense a new gas— a very inconvenient and costly task. 


Not only that, but their existing system was a rat’s nest of wires with little to no drawings. It was retrofitted so many times to the point where nobody understands how the system functions anymore. In fact, the customer was having a difficult time finding anyone with the knowledge and expertise to help them. That is when the Neal Systems team came to help.



After troubleshooting and testing the pre-existing equipment to know how everything worked together, Neal Systems demolished obsolete portions of the existing cabinet and repurposed what we could. Their existing equipment was retrofitted with a new Draeger Regard 7000 enclosure, several Draeger Polytron 7000 transmitters, gas detectors, and new light stacks. Our solution simplifies the process to exchange sensors, and the controller can recognize exchanged sensors and recommend settings based on what is plugged in.

The Big Reveal

Our solution allows the customer to change out multiple gas sensors with relative ease. The system can recognize the different sensors that are plugged into the transmitters, and even recommend when the sensor life is near an end so that they can be proactively changed out. The customer no longer has the hassle of replacing detectors when they need to monitor new gases. We’ve also updated the drawings so that future work and expansion of the system would be feasible. The solution we provided to our customer was cost-effective, quick, and efficient, thanks to Neal Systems’ Engineering team and Draeger’s advanced technology, especially the Regard 7000 Gas Detection System.





Draeger Polytron 7000

Draeger Electrochemical (EC) Sensor

Draeger Regard 7000

Engineering Inquiry? Contact us here and we will be in touch!

Job Note: Waste Water Treatment Plant Scada Upgrade

January 31, 2024 | Application NoteMunicipal: Water


Waste Water Treatment Plant
Northeast, USA
Construction Costs: $250K

Waste Water Treatment Plant
Northeast, USA
Construction Costs: $250K

Services Provided

  • SCADA Systems

  • Remote I/O Racks & OIT’s

  • PAC Control System

  • Wireless Communication


  • Cyber Security Consulting

  • Enclosures

  • Installation Services


SCADA upgrade for gas detection, alarm annunciator replacement, wet well, MSP’s, DO tanks, digesters, hypo tanks, chlorine control and final effluent including all field devices, enclosures and communication systems.

Our customer’s previous system covered only half the plant and did not provide any reporting or reliable alarming. The operators never used the system because of communication failures and unreliable data.

The system NSI designed was entirely Ethernet based, but used copper, fiber, and wireless to reach all areas. Cyber security was designed into the system with whitelisting and MAC address filtering along with a firewall performing deep packet inspection. Different remote I/O racks, multi-loop controllers, PAC’s and OIT’s were used to bring in the 400 new I/O points— all using either Modbus RTU or Modbus TCP.

NSI brought a specific expertise in Chlorine dosing control to the facility, reducing their Sodium Hypochlorite consumption by 15% whilst improving the stability of the residual Chlorine.

The plant finished up with a system that included all areas allowing operators to monitor a sizeable area from a central location. Remote view nodes using a browser allowed management to interrogate the plant at any time and the added reports allowed for more effective regulatory compliance.

Cyber Security Warning: Water and Sewage-Treatment Municipalities

December 7, 2023 | Company News



Attacks on American infrastructure show no signs of abating. Various threat actors have expressed intentions to undermine the American way of life by targeting crucial infrastructure components. The recent breach of a water treatment pump station in Western PA underscores the urgent need to refocus our efforts on enhancing security measures.

Security stands as the cornerstone of every controls project that NSI has consulted on. While “security” is commonly mentioned as a buzzword, few grasp the intricacies of the complex devices that implement protection right down to the packet level.



Outlined below are some fundamental aspects of security implementation:

Password Management

Infiltration often starts with the basics. The default password remains the easiest gateway for unauthorized access. Failing to change the default to a more robust password exposes vulnerabilities to threat actors. Managing user access as they transition within an organization can significantly reduce    potential vulnerabilities in your control architecture.

Network Isolation

Does your network truly need constant connectivity to the global internet? Have you explored the use of virtual private networks or private APNs for remote assets to shrink the network’s surface area? Evaluate the necessity of connectivity. Consider the open ports on the network’s edge and their essentiality.

Support and Updates

Are you consistently updating your network’s software to the latest versions? Has your SCADA system addressed critical vulnerabilities in recent updates? Threat actors continually adapt their attack methods. Software that was secure last year may now be vulnerable. It’s crucial to stay ahead and ensure ongoing updates for your most critical assets.



Are you consistently updating your network’s software to the latest versions? Has your SCADA system addressed critical vulnerabilities in recent updates? Threat actors continually adapt their attack methods. Software that was secure last year may now be vulnerable. It’s crucial to stay ahead and ensure ongoing updates for your most critical assets.

Ask yourself the following questions. If any of your answers make you nervous then NSI Neal Systems can offer assistance:

1. Do you truly understand your network and is there a diagram showing all device make / model plus all connections? 

2. Have you reduced or eliminated your exposure to the outside world i.e. Internet connections, remote access ports, allowance of USB sticks, cell modems and radios?

3. For the access that is available, have you reduced the number of people that can use it and do you support multi-factor authentication?

4. Do you have a firewall at the edges of your network?

5. Do you have a dedicated Industrial cyber security device that understand Modbus TCP, EtherNet IP and DNP3 and can examine each data packet as it passes through?

NSI works with hundreds of water facilities, private and municipal, from PA to NY to NJ to DE to MD to VA.  We help with wireless systems, controls, RTUs, SCADA, and instrumentation.  What you may not know is that we can help you with cybersecurity! Contact NSI today!

For more information on this topic click here!

Unlocking Precise Dew Point Measurement with the Portable XPDM Dew Point Meter

October 30, 2023 | Product News


In various industries, the need for quick and accurate dew point measurements is undeniable. Whether you’re involved in natural gas processing, the petrochemical industry, HVAC systems, power generation, pharmaceuticals, or food processing, having a reliable instrument for spot-checking moisture in gases and liquids is crucial. That’s where the COSA XENTAUR™ Portable XPDM™ Dew Point Meter steps in, providing a portable and easy-to-use solution for accurate dew point measurements.

The Portable XPDM Dew Point Meter is a versatile tool with a wide range of applications. Here are some of the key industries that benefit from its capabilities:

Natural Gas Processing: Measure moisture content in natural gas pipelines, storage tanks, and processing facilities to ensure safety and efficiency in the natural gas system.

Petrochemical Industry: Use the XPDM to measure moisture content in various gases and liquids, including propane, butane, and other hydrocarbons.

HVAC Systems: Measure moisture content in HVAC systems to optimize performance and prevent issues caused by excess moisture, such as mold growth.

Power Generation: Ensure the efficiency and safety of power generation processes by measuring moisture content in steam and other gases in power plants.

Pharmaceutical Industry: Maintain the quality and stability of drugs and other products by measuring moisture content in the pharmaceutical industry.

Food Processing: Ensure the quality and safety of various food products by measuring their moisture content.



The Portable XPDM Dew Point Meter comes packed with a range of features to meet your moisture measurement needs:

High Accuracy: Provides highly accurate dew point temperature measurements with an impressive accuracy of up to ±0.2°C.

Wide Measuring Range: Measures dew point temperatures from as low as -110°C to as high as 20°C, suitable for a wide array of applications.

Fast Response Time: Offers real-time measurements with a response time of less than 5 minutes, allowing for swift assessments.

User-Friendly: Designed for ease of use with a clear and intuitive display and simple one-button operation.

Portable: Its lightweight and compact design make it easy to carry and use in the field.

Versatile: Capable of measuring the moisture content of various gases and liquids, including natural gas, compressed air, hydrogen, nitrogen, and more.

Data Logging: Store up to 10,000 measurement data points, which can be easily downloaded and analyzed later using the included software.

Durability: Built to withstand harsh industrial environments and boasts a long battery life.

Spancheck™ – Ensuring Calibration in the Field

One unique feature of the Portable XPDM Dew Point Meter is the Spancheck™ function, which plays a crucial role in maintaining the instrument’s accuracy over time. Spancheck allows users to check the calibration of the instrument right in the field, which offers several benefits:

Ensures Accuracy: Quickly and easily check the accuracy of the instrument on-site, ensuring reliable measurements without additional equipment or specialized skills.

Saves Time and Money: Eliminates the need to send the instrument for periodic calibration checks, reducing downtime and saving costs.

Increases Productivity: Verify the calibration on-site, enhancing productivity and efficiency in your operations.

Reduces Risk: Reduces the risk of inaccurate measurements, which can lead to costly errors or safety hazards in various applications.



The Portable XPDM Dew Point Meter comes with a range of benefits, including:

HTF™ Sensor Technology: Ensures extremely fast response times.

Portable Measurements: Easy-to-carry and use in various applications.

Sensor Technology: Reliable and accurate measurements.

Single Point Calibration: Simplifies the calibration process.

Six Different Engineering Units: Offers flexibility in measurement.

Spancheck™ in the Field: Ensures ongoing accuracy.

Special Long-Life Battery: Provides up to 100 hours of continuous monitoring.

Carrying Case Available: An optional accessory for added convenience.


The versatility of the Portable XPDM Dew Point Meter extends to various applications, including:

  • Cryogenic Gas Producers
  • Custody Transfer
  • Electrical Insulating Gases
  • Feedstock Gases
  • Gas Cylinders and Air Separation Plants
  • Instrument Air
  • Natural Gas Pipelines
  • Petrochemical
  • SF6 Moisture Measurements
  • Shipboard LNG and Aviation Oxygen
  • Specialty Gas Producers

The COSA XENTAUR™ Portable XPDM™ Dew Point Meter is a game-changer for industries that require accurate dew point measurements. With its high accuracy, wide measuring range, fast response time, and user-friendly design, it’s a reliable tool for on-site moisture content assessment. Additionally, the Spancheck™ feature ensures ongoing calibration accuracy in the field, saving time and money. In a wide range of applications, this portable dew point meter proves to be an indispensable asset for optimizing processes, ensuring safety, and maintaining product quality.


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