Company News

Do you need wired or wireless vibration monitoring?

February 13, 2020 | Company News

Over the past year, Neal Systems has been researching, testing, integrating and deploying combination vibration monitoring systems using both wired and wireless technology. There are benefits and drawbacks of both wired and wireless, but when paired together the accuracy and reliability of your system becomes unmatched.

Wireless vs Wired

The Benefits of Wired Vibration Monitoring

Reliability: The 4-20mA current loop has set the standard for industrial signal reliability. The Neal Systems enhanced solutions are unrivalled in reliability due to its consistent signal accuracy over the typical life span of a loop-powered field instrument.  

Continuous Data: The wired solutions provided by Neal Systems record vibration data continuously, ensuring that any sudden changes in the overall vibration levels are captured and recorded. This allows for the most accurate understanding of your equipment function.

The Drawbacks of Wired Vibration Monitoring

Installed Cost: The installation of a new wired sensors on standard wired vibration monitoring usually requires new conduit and expanded I/O on the PLC.    

Convenience:  Wired data has to be viewed locally, either at the indicator on the instrument or from the control room using SCADA software.  

Diagnostic Power: Wired solutions usually use 4-20mA outputs, which simplify the data down to overall levels and loose the frequency information. 

The Benefits of Wireless Vibration Monitoring

Installed Cost:  Wireless solutions are particularly cost effective.

Convenience: With Neal Systems cloud-based wireless solutions, any device with an internet connection and log-in credentials can access trends and alarms.

Diagnostic Power:  Wireless solutions offer more advanced data processing and diagnostic capabilities. This is due to the computational “heavy lifting” that is done by remote servers.

The Drawbacks of Wireless Vibration Monitoring

Reliability: Even the most robust wireless systems are subject to downtime. Whether it’s a neighboring plant blasting electromagnetic noise on your frequency, a box truck conveniently parked next to your base station, or a new construction in the path of your signal.

Non-Continuous Data: Modern data speeds are fast, but not fast enough to continuously transmit the high frequency data sampling rates needed for most vibration applications.  To deal with this challenge, most wireless vibration solutions record and transmit small windows of vibration data in regular intervals.  The recording window is usually less than 1 sec and the interval between recording windows on the Neal Systems choice solution is 5 minutes.

How do these two vibration monitoring solutions fit together?

In our experience, the best monitoring systems use a combination of both wireless and wired components.  The drawback of costs of a wired solution can be minimized with loop-powered Neal Systems enhanced solutions: the Metrix ST5484E and the Metrix MX2034. These options reduce installation and I/O requirements, which in turn lowers costs. These specific styles of sensors also have a long history of providing reliable and accurate alarms for increasing or decreasing vibration.  

The wired solutions, Metrix ST5484E and the Metrix MX2034, when paired with the wireless Samsara HM11 and IG21, allow for in-depth diagnostics on regular intervals or in the event of an alarm. Also, by pairing a wireless option with the wired solution you are able to quickly and remotely able to access information on your system.

Choosing to go with the combination wired and wireless solution, will increase efficiency and reliability, which lowers cost and allows for preventative maintenance to occur before equipment malfunctions result in system failure.

Check out this graphic for a quick glance of each solution! 

NSI Expands MTL Representation into Virginia

January 27, 2020 | Company News

Neal Systems is proud to announce that in the Fall of 2019, NSI was selected to extend our MTL representation into Virginia.  MTL Instruments, an Eaton company, is one of the premiere suppliers of intrinsically safe products and solutions for hazardous areas, as well as providing surge protection for instrumentation, electrical panels, and plant mains. 

Neal Systems has been a representative and hazardous area expert for MTL since the mid-80s, and have multiple technical experts and engineers who can assist you with any of your hazardous area needs. 

Industrial Biogas: Accurate Analyzation of CH4, O2, HS2 and CO2

January 20, 2020 | Company News



Industrial biogas is a byproduct of several processes within a variety of industries. If your process includes biogas as a byproduct, then the accurate and consistent measurement of the biogas’ makeup is essential in maximizing its commercial value and ensuring safe and compliant operations of your plant and process.


The Four Main Components: Methane, Oxygen, Hydrogen Sulfide, and Carbon Dioxide

Methane Measurements
: Methane (CH4) being the primary component, the measurement of its composition and quality is essential in maximizing the benefits from private and government-backed incentives for this biogas to be used as a fuel source. 

Oxygen Measurements: Accurate and reliable measurements of oxygen (O2) is critical in maintaining the appropriate levels of saturation to prevent the generation of explosive mixtures of methane (CH4) and oxygen (O2). These measurements also ensure efficient levels of microbial activity to eliminate the potential for oxygen to poison an anaerobic digestion process. 

Hydrogen Sulfide Measurements:  The corrosive, flammable and poisonous nature of hydrogen sulfide make it necessary to ensure that the hydrogen sulfide (H2S) level is maintained at level of ideally less than 200ppm, minimizing the potential for corrosion when the condensing gas forms sulfuric acid. 

Carbon Dioxide Measurements: Carbon Dioxide (CO2) is used as an effective indicator of efficiency of an anaerobic digester performance. Understanding the performance of the digester is instrumental in keeping your product and plant protected. 


The Neal Systems Solution


Neal Systems expertise in engineering, installing, and servicing gas analyzation and detection systems is unrivaled in the industry. Whether you are producing solid products, liquid products, fuel, thermal or electricity our team can provide you with the most accurate and reliable gas analyzers and detection systems available.

Our top choices for gas analyzation and gas detections include: Hitech (aka Eaton MTL Gas), Servomex, and Draeger. With these products, our team can build an efficient and effective solution to keep your process maintained at the highest level to protect and ensure safety and the quality of your product. 

For more information on how Neal Systems can provide the best solution for your process, please contact us here

Pipe Freeze: Solution Success

December 20, 2019 | Company News

The winter months bring low temperatures, which leads to the risk of pipes freezing and bursting. A burst pipe can cause a catastrophic failure in some plants. Recently, a Neal Systems engineered solution mitigated this risk and allowed for preemptive action to be taken to avoid a shutdown and costly repairs.

The image shown, shows the temperature inside an enclosure containing controls for the liquid flowing in-to and out of a large tank. At 06:40 AM the tank temperature hit a low of 16 degrees Fahrenheit. This monitoring allowed for our customer to take action immediately to avoid a costly shutdown and repair.

Our solution consisted of a Eurotherm 2500/VersaDac I/O which collected the data from the piping system via 4 to 20 mA signals from temperature, tank and flow levels using a Foxboro IDP10S and a Foxboro RTT15S.

The data was transmitted using a Red Lion Cellular Data Modem in a PLC and a Eurotherm 6180A Recorder. Eurotherm’s Review software produced the image shown, which was being remotely monitored by the customer.

Neal Systems expertise in designing and supplying cost effective solutions, saved our customer tens of thousands of dollars in repairing freeze damage to pipes.

For more information on this or other NSI solutions contact us here!


December 9, 2019 | Company News

 Neal Systems has teamed with Lambda Square to create the NSI Orifice Plate Assembly (OPA), a pre-assembled, simplified flow measurement solution.


NSI’s team of engineers are here to help with the challenges of specifying, sizing, and assembling a total differential pressure flow-based measurement package.

Our custom-designed Orifice Plate Assembly, the NSI OPA, solution utilizes a Lambda Square orifice plate, a high-accuracy Foxboro by Schneider Electric differential pressure transmitter (just one, not two!), and a pre-fabricated flange assembly containing all necessary connection materials.

Most flow projects utilizing an orifice plate often have three major challenges:

  1. Two differential pressure transmitters are typically required for wide range flow applications. Traditional DP transmitters have poor accuracy on the low-end of the scale. This causes significant errors in the flow calculation.
  2. Inaccurate process conditions can result is poorly sized orifice plates
  3. Customized parts often have long lead-times leading to long down-times

The Neal Systems Orifice Plate Assembly has been engineered to overcome these three challenges.

Our solution solves the first issue of needing two transmitters and flow calculation errors by utilizing a single differential pressure transmitter that has a 0.025% reading accuracy across 88% of the full range – the Foxboro by Schneider Electric IDP50S. Reading accuracy means the error decreases as the measurement decreases. Using the IDP50S means that for the vast majority of flow applications, you do not need a second transmitter for low-flow. In addition, the flow calculation has the same superior accuracy across the 88% of the usable transmitter range, not just at the measurements high point.

The second challenge, inaccurate process conditions, is addressed by our OPA design form, which can be viewed HERE. Our team of application engineers will gather your information and design the optimal orifice plate and options for your application. We will also provide a size up and size down in order to have a back-up plan should conditions change.

And finally, our solution to long lead times is handled by utilizing mostly stock parts for all of our assembly – the transmitter, 3-valve manifold, orifice plate, and mounting assembly are all stocked items that can be quickly ordered replaced and installed should there be an issue.

Additional Options

The NSI Orifice Plate Assembly has an additional option for steam applications. For saturated steam applications we can convert flow to mass by adding a Eurotherm by Schneider Electric Nanodac. The Nanodac can generate a saturated steam table with inputs for flow, pressure, and temperature.

Speak directly to one of our engineers about the NSI OPA by contacting us here!

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