Application Note

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.

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