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Anhui Tongcheng Plate Making Enterprise Sewage Treatment Station GNST-SC1000 Online COD Ammonia

Date: 2025-12-24Read: 1

Installation and commissioning case of GNST-SC1000 online COD ammonia nitrogen total phosphorus total nitrogen detector for sewage treatment station of Anhui Tongcheng plate making enterprise

1、 Project Background and Overview

（1） Project Background

As a gathering place for the printing and plate making industry, Tongcheng, Anhui Province, the wastewater generated by local plate making enterprises in the production process mainly comes from processes such as plate flushing and washing, containing core pollutants such as COD, ammonia nitrogen, total phosphorus, and total nitrogen, accompanied by a small amount of suspended solids and organic additives, resulting in significant fluctuations in wastewater quality. In order to strictly implement environmental control requirements and ensure stable and compliant discharge of wastewater after treatment, a large plate making enterprise in Tongcheng has set up monitoring points at the discharge outlet and key treatment units of its factory's sewage treatment station, equipped with GNST-SC1000 online COD ammonia nitrogen total phosphorus total nitrogen detector. This device has the characteristics of IP68 high protection level, strong anti-interference ability, and high detection accuracy. It is equipped with an integrated GSM/GPRS modem, supports multi band communication, and can achieve 24-hour continuous monitoring and remote data transmission of four core indicators. It is suitable for the complex working conditions of enterprise workshops and the continuous operation needs of sewage treatment stations. The installation and debugging work is led by the technical team of Henan Suijing Environmental Protection Technology Co., Ltd., with the cooperation of the enterprise's environmental protection department and operation and maintenance department, to ensure the accurate docking of equipment with sewage treatment processes, guarantee the authenticity and effectiveness of monitoring data, and provide data support for the enterprise's environmental compliance and process optimization.

（2） Core objective

Theoretical level: Enable trainees to understand the detection principle, core technical indicators, and national standard basis of GNST-SC1000 instrument, and clarify the applicable scenarios for testing different water quality indicators.
Practical level: Ensure that trainees are proficient in the entire process of instrument startup self check, parameter calibration, sample preparation and testing, data storage and export, and can independently complete the testing of typical water quality indicators.
Guarantee level: Master the common troubleshooting methods and daily maintenance points of instruments, extend the service life of instruments, and ensure the long-term stability and reliability of detection data.
Application level: To achieve deep integration of theory and scientific research practice, enhance the ability of trainees to use instruments to solve practical scientific research problems, and lay the foundation for the smooth progress of related environmental monitoring scientific research projects.
Standardized installation: Complete the layout of the GNST-SC1000 detector host, sampling system, pretreatment device, power supply, and GPRS transmission module in the workshop and on-site sewage treatment station, ensuring that the installation complies with the requirements of the "Technical Specification for Installation of Online Monitoring System for Water Pollution Sources (COD? Cr?, NH? - N, etc.)" (HJ 353-2019).
Accurate debugging: Based on the fluctuation characteristics of the water quality of plate making wastewater, precise calibration and performance testing of COD, ammonia nitrogen, total phosphorus, and total nitrogen indicators have been completed to ensure that the indicators such as indication error, repeatability, and 24-hour drift meet the standards, ensuring that the equipment is suitable for monitoring high concentration organic wastewater.
System linkage: Ensure stable networking between GNST-SC1000 equipment and enterprise environmental monitoring platform, relying on its Modbus TCP communication protocol to achieve real-time uploading of monitoring data and normal response to abnormal warning functions, meeting the online supervision requirements of environmental protection departments.
Long term guarantee: Formulate a GNST-SC1000 model standardized installation and commissioning manual and operation and maintenance points that are suitable for the characteristics of enterprise wastewater, providing technical support for the long-term stable operation of equipment and environmental compliance management of enterprises.

2、 Training preparation

（1） Organizational Structure

1. Host: Environmental Science Research Center, Yangtze River Delta Research Institute, University of Electronic Science and Technology of China (Huzhou)

2. Supporting unit: Henan Suijing Environmental Protection Technology Co., Ltd

3. Training instructor: Senior technical engineer from the supplier (with rich experience in GNST-SC1000 instrument debugging and training)

4. Trainees: 22 members of the research team related to environmental monitoring and experimental technicians from the research institute

（2） Preliminary preparation

Site and equipment preparation: The standardization laboratory of the research institute is selected as the training site, and the operation table is organized in advance to ensure good ventilation and that the temperature and humidity meet the requirements for instrument operation (temperature 5-40 ℃, relative humidity ≤ 85% RH). Place the GNST-900S host, multifunctional intelligent digestion instrument, supporting testing tubes, prefabricated reagents and other equipment and materials in place according to the operating line, complete the power connection and power on self-test, and ensure that all equipment is in normal working condition; Prepare calibration solution, simulated water sample, deionized water, lens cleaning paper and other practical consumables at the same time.
Site preparation: Clean up the debris on the installation site, build anti-corrosion protective sheds at the monitoring points of the sewage treatment station, and level the equipment installation base; Excavate the cable trench according to the design path, carry out anti-corrosion, waterproof and anti-seepage treatment, seal the cable trench cover to prevent wastewater leakage and pollution.
Safety protection: Set up construction warning signs, equip with safety helmets, anti-corrosion gloves, protective goggles and other protective equipment; Check the insulation performance of construction tools, and develop ventilation protection and hot work safety plans for potential organic volatile compounds in the workshop.

Refinement of the plan: The technical team communicated with the person in charge of the enterprise's environmental protection department in advance, combined with the characteristics of large fluctuations in the water quality of the plate making wastewater and easy blockage of pipelines by suspended solids, to refine the installation and commissioning plan in a targeted manner, focusing on clarifying the operational standards of key links such as corrosion protection of the GNST-SC1000 host, selection of filtration accuracy for pre-treatment devices, and setting of calibration parameters for high concentration wastewater, to ensure that the plan meets the actual operational needs of the enterprise's sewage treatment plant.

3、 Installation Implementation Process

The installation implementation strictly follows the HJ 353-2019 standard and equipment installation specifications, and follows the process of "core equipment installation → pipeline connection → system integration debugging". The specific steps are as follows:

（1） Installation of core equipment

1. Host installation: Fix the GNST-SC1000 host on a dedicated bracket inside the anti-corrosion protection shed, ensuring that the body is level, well ventilated, and the straight-line distance from the sampling port does not exceed 5m (reducing pipeline losses); The host interface faces inward and is sealed with specialized anti-corrosion sealing components to prevent corrosion from acidic and alkaline gases in the workshop and pollution from wastewater splashing.

2. Installation of sampling system: According to the requirements of HJ 353-2019, install the sampling probe in the main flow area of the sewage treatment plant discharge outlet and biochemical unit outlet, ensuring that the probe is submerged and avoids dead corners of water flow; The sampling pipeline adopts corrosion-resistant polytetrafluoroethylene hose, and the pipeline laying slope is not less than 1% to avoid the formation of water accumulation bends; Install a high-precision pre filtration device (with a pore size of 3 μ m) to specifically solve the problem of suspended solids blockage in plate making wastewater. The filtration device is equipped with a backwash function for easy daily maintenance and cleaning.

3. Installation of power supply system: The workshop industrial electricity (AC 220V) is used for power supply, and a dedicated regulated power supply and leakage protection device are installed to ensure stable power supply voltage and avoid voltage fluctuations caused by the start and stop of workshop equipment affecting instrument operation; The power line is laid with anti-corrosion and waterproof conduit, and grounding treatment is done well.
4. Installation of transmission module: Connect the GPRS transmission module to the GNST-SC1000 host data interface and fix it in the signal good area inside the protective shed; Insert the IoT SIM card, test the signal strength (ensure ≥ 3 grids), and complete the dual network adaptation with the enterprise environmental monitoring platform and local environmental protection department supervision platform through the device Modbus TCP protocol. Configure the data upload frequency (1h/time) and communication parameters.

（2） Pipeline and line connection

1. Pipeline connection: Connect the sampling probe → pre filtering device → main engine sampling port in sequence. The pipeline interface is sealed with a sleeve type anti-corrosion seal. After connection, perform pressure testing (no leakage under 0.1MPa pressure); Install the backwash pipeline and waste liquid recovery pipeline, connect the backwash pipeline to the host and sampling probe, and ensure that the filtration device is regularly and automatically backwashed; The waste liquid recycling pipeline is connected to the enterprise's sewage treatment system to avoid secondary pollution.

2. Instrument initialization: Demonstrate the GNST-SC1000 power on self-test process and explain how to determine the operating status of the instrument hardware (display screen, buttons, light source) and software system; Introduce the parameter adjustment method of the system settings interface, combined with the emission standards of the plate making enterprise, configure key parameters such as detection cycle, alarm threshold (refer to the third level standard setting of the Comprehensive Wastewater Discharge Standard (GB8978-1996)), data upload protocol, etc.

2. Line connection: Connect the main unit to the sampling pump, preprocessing device, power supply system, and transmission module according to the equipment manual; All lines shall be laid with anti-corrosion and waterproof conduit, and the conduit interface shall be sealed properly; Mark both ends of the line for easy maintenance.

3. Grounding treatment: The equipment casing, protective shed, and power supply system all need to be grounded with a grounding resistance of ≤ 4 Ω to prevent electromagnetic interference and lightning damage to the equipment in the workshop; Install lightning protection devices around the protective shed to ensure that the equipment is within the lightning protection range.

4、 Debugging core process

The debugging work strictly follows the requirements of HJ 354-2019 standard, combined with the characteristics of large fluctuations in the water quality of plate making wastewater. The debugging of COD, ammonia nitrogen, total phosphorus, and total nitrogen indicators is carried out in modules to ensure that the equipment performance meets the standards:

1. System initialization and debugging: Start the GNST-SC1000 device, complete the power on self-test, and check the operating status of the host, sampling system, preprocessing device, power supply, and transmission module; Configure basic parameters in the system settings interface, including detection indicators, detection cycle (set to 1 hour/time), data upload frequency, and alarm threshold (set according to the third level standard of the Comprehensive Wastewater Discharge Standard (GB8978-1996)).

2. Precise calibration and debugging: In response to the high COD concentration of plate making wastewater, a three-point calibration method is used to calibrate four indicators separately. After cleaning the detection channel three times with deionized water, blank solution, low concentration standard calibration solution, and high concentration standard calibration solution are added in sequence. After the readings stabilize, the calibration parameters are saved; After calibration is completed, verification is carried out using an intermediate concentration standard solution for testing, and the indication error must meet the requirement of ≤± 10%. Among them, the calibration of total phosphorus and total nitrogen requires the completion of parameter debugging of the digestion module in advance to ensure accurate control of the digestion temperature (total phosphorus 120 ℃, total nitrogen 125 ℃) and digestion time (both 30 minutes).

3. Performance testing and debugging: Conduct a 72 hour continuous operation test (in accordance with the requirements of industrial online monitoring equipment debugging), monitoring at three concentration points of 20%, 50%, and 80% of the detection range, with a 24-hour drift of ≤± 5% F.S; Repeat the test 6 times for each concentration point, with a repeatability of ≤ 5%; Comparative testing was conducted on actual plate making wastewater samples from enterprises, and the relative error between equipment measurements and laboratory standard method measurements was ≤± 15% to ensure data accuracy.
4. System linkage debugging: Test the linkage performance of the entire process of automatic sampling, preprocessing, detection, and data upload; Simulate high concentration COD exceeding the standard scenario, verify the synchronous response of local alarm and platform alarm functions of the equipment, and require that both the enterprise environmental monitoring platform and the environmental protection department supervision platform receive alarm information within 5 minutes; Test the stability of GPRS transmission to ensure a data upload rate of ≥ 99%.

Technical briefing: The supplier's technical personnel conducted a special technical briefing on GNST-SC1000 equipment to the enterprise's operation and maintenance personnel, focusing on explaining the daily maintenance points of the equipment for plate making wastewater (such as the backwash cycle of the pre filtration device, the cleaning method of the channel after high concentration wastewater detection, and the standard for reagent replacement), data interpretation, and common troubleshooting methods to ensure that the operation and maintenance personnel have independent operation and maintenance capabilities.

5、 Acceptance and delivery

1. Acceptance content: The acceptance team is jointly composed of the enterprise's environmental protection department, suppliers, and third-party environmental testing institutions. They compare the installation and commissioning plan with relevant standards, inspect the equipment installation standardization, 72 hour continuous operation stability, four indicators testing performance (indication error, repeatability, drift), data upload accuracy, and alarm function effectiveness, and synchronously verify the equipment's connection with the environmental protection department's regulatory platform.

2. Data delivery: After passing the acceptance inspection, the supplier shall deliver a complete set of materials to the enterprise, including installation and commissioning reports, equipment manuals, calibration records, 72 hour operation test reports, quality assurance documents, and operation and maintenance manuals (including targeted maintenance points and common fault troubleshooting methods) adapted to the plate making enterprise.

6、 Project effectiveness

Stable Equipment Operation: After installation and debugging, the GNST-SC1000 detector has achieved stable operation in complex working conditions in enterprise workshops and continuous operation environments in sewage treatment plants. The continuous upload rate of monitoring data for four core indicators is ≥ 99.5%, and the equipment failure rate is less than 1%. It is suitable for monitoring requirements with large fluctuations in wastewater quality and suspended solids.

Environmental compliance guarantee: The equipment realizes 24-hour continuous monitoring of the core indicators of plate making wastewater, and the data is real-time connected to the enterprise environmental monitoring platform and the local environmental protection department supervision platform, effectively avoiding the risk of exceeding environmental standards; Through data anomaly warning, two incidents of fluctuation in sewage treatment processes were detected and dealt with in advance, ensuring that the effluent quality remained stable and met the third level standard of the Comprehensive Wastewater Discharge Standard (GB8978-1996), and ensuring the environmental protection and compliance of the enterprise's production.

Operation and Maintenance Management Standards: Based on the characteristics of GNST-SC1000 equipment and the monitoring requirements for plate making wastewater, a targeted instrument usage registration system, regular calibration (once a month), and maintenance system have been established. The operation and maintenance personnel have clarified the equipment management responsibilities, effectively reducing the incidence of instrument failures and extending the service life of the equipment.

Process optimization support: Based on continuous monitoring data from equipment, the environmental protection department of the enterprise analyzes the changes in wastewater quality under different production conditions, providing data support for adjusting sewage treatment process parameters, achieving precise dosing of chemicals, and reducing sewage treatment costs by about 8%.

5、 Experience Summary and Prospect

（1） Experience summary

Water quality adaptation is key: This installation and debugging fully combines the characteristics of large fluctuations in water quality, suspended solids, and high COD concentration in plate making wastewater. Targeted optimization of sampling pretreatment schemes and calibration methods is carried out, and corrosion-resistant material accessories are selected to ensure precise adaptation of equipment to plate making enterprise wastewater treatment scenarios, laying the foundation for data accuracy.

School enterprise collaboration is a guarantee: the efficient collaboration between enterprises and instrument suppliers ensures that installation and commissioning plans are in line with the actual production conditions of the enterprise. The establishment of subsequent technical support mechanisms provides strong support for solving complex problems in long-term equipment operation, such as interference from high concentration wastewater detection and pipeline corrosion.

（2） Future prospects

Subsequent enterprises will further enhance their environmental monitoring capabilities based on the results of this installation and commissioning: firstly, expand the deployment range of GNST-SC1000 equipment, add monitoring points in the pretreatment unit, and achieve full process water quality monitoring of sewage treatment; Secondly, relying on the advantages of equipment data transmission, we will deepen the linkage analysis between monitoring data and production conditions, optimize the coordinated control of production processes and sewage treatment processes; The third is to continuously deepen cooperation with suppliers, timely follow up on equipment technology upgrades, optimize monitoring plans in combination with new environmental regulations in the plate making industry, and provide stronger support for the green and sustainable development of enterprises.