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Monitoring Case of Sewage Treatment Station in Meizhou Electroplating Plant, Guangdong Province

Date: 2025-12-24Read: 1

Installation and commissioning case of GNST-SC1000 online monitoring equipment for sewage treatment station of Meizhou Electroplating Plant in Guangdong Province

1、 Project Background and Overview

（1） Project Background

As an important manufacturing base in eastern Guangdong, Meizhou City, Guangdong Province, the electroplating industry is one of the local characteristic industries, mainly involving surface treatment of hardware accessories, electronic components and other products. The composition of electroplating wastewater is complex, containing heavy metal ions such as chromium, nickel, copper, as well as characteristic pollutants such as COD and pH. If not treated properly and discharged directly, it will cause serious harm to the surrounding water bodies and soil ecological environment. In order to strictly implement the requirements of the "Emission Standards for Electroplating Pollutants" (GB 21900-2008) and strengthen the full process control of wastewater treatment, a large-scale electroplating plant in Meizhou City has set up monitoring points at the drainage outlet of the electroplating workshop, the outlet of the comprehensive wastewater pretreatment unit, and the main discharge outlet, constructed standardized monitoring stations, and equipped GNST-SC1000 online multi parameter monitoring equipment. This device has the characteristics of strong acid and alkali corrosion resistance, strong resistance to heavy metal interference, and high detection accuracy. It is equipped with Ethernet+GPRS dual transmission modules, which can achieve 24-hour continuous monitoring and remote data transmission of core indicators such as COD, pH, total chromium, hexavalent chromium, and total nickel. It is suitable for the monitoring needs of electroplating wastewater with large fluctuations in water quality and strong corrosiveness. The installation and debugging work is led by the technical team of Henan Suijing Environmental Protection Technology Co., Ltd., with the cooperation of the environmental protection operation and maintenance department of the electroplating plant, to ensure the accurate docking of equipment with the wastewater treatment process, guarantee the authenticity and effectiveness of monitoring data, and provide data support for the standard discharge of electroplating wastewater and environmentally compliant production.

（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 workshop layout of GNST-SC1000 monitoring equipment host, dedicated sampling system, heavy metal pretreatment device, power supply and dual transmission module, ensuring that the installation complies with the "Technical Specification for Installation of Online Monitoring System for Water Pollution Sources (COD? Cr?, NH? - N, etc.)" (HJ 353-2019) and the construction requirements of monitoring station buildings for electroplating enterprises.
Accurate debugging: Targeting the characteristics of large fluctuations in heavy metal concentration, strong corrosiveness, and complex composition in electroplating wastewater, precise calibration and performance testing of core indicators such as COD, pH, total chromium, hexavalent chromium, and total nickel are completed to ensure that indicators such as indication error, repeatability, and 24-hour drift meet the standards.
System linkage: Ensure stable networking between GNST-SC1000 equipment and the supervision platform of Meizhou Ecological Environment Bureau and the intelligent control platform for environmental protection of electroplating plants, relying on its Modbus TCP communication protocol to achieve real-time uploading of monitoring data and normal response of abnormal warning functions, meeting the requirements of online monitoring of key pollution sources.
Long term guarantee: Establish a standardized installation and commissioning manual and operation and maintenance points for GNST-SC1000 model suitable for electroplating wastewater monitoring, providing technical support for the long-term stable operation of equipment in corrosive environments.

2、 Training preparation

（1） Organizational Structure

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

2. Training instructor: Senior technical engineer from the supplier (with rich experience in GNST-900S instrument debugging and training)

3. 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: Construct standardized monitoring stations according to specifications, adopt anti-corrosion and explosion-proof design, and equip with two-way air conditioning for cooling and heating to ensure controllable insulation and humidity (temperature 5-40 ℃, relative humidity ≤ 85% RH); Flatten the equipment installation base and carry out anti-corrosion and anti-seepage treatment on the ground of the station building; Lay anti-corrosion pipeline protection pipes and cable sleeves according to the design path, ensuring that the pipelines and cables are away from the area where acidic and alkaline waste liquids flow.
Safety protection: Set up construction warning signs and protective fences, equip with acid resistant gloves, protective face masks, anti slip and anti-corrosion shoes and other specialized protective equipment; Check the insulation and anti-corrosion performance of construction tools, develop emergency response plans for acid and alkali leaks, equip emergency neutralizing agents and fire-fighting equipment in the station building, and strengthen workshop construction safety protection.

Refinement of the plan: The technical team communicated with the operation and maintenance manager of the electroplating plant in advance, combined with the characteristics of high heavy metal content, strong corrosiveness, and large fluctuations in water quality with production conditions in electroplating wastewater, to refine the installation and commissioning plan in a targeted manner. The focus was on clarifying the operational standards for key links such as the GNST-SC1000 host anti-corrosion fixing method, heavy metal pretreatment device parameter settings, corrosion-resistant pipeline selection, and data integration with the supervision platform of the Municipal Ecological Environment Bureau, to ensure that the plan meets the actual operational needs of the electroplating 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 anti-corrosion bracket in the standardized monitoring station building. The bracket is made of stainless steel material and is securely connected to the ground expansion bolt to ensure that the body is level and well ventilated, with a straight-line distance of no more than 5m from the sampling port (reducing pipeline losses); The host interface faces inward and is sealed with fluororubber seals to prevent corrosive gases from affecting equipment operation in the station building.

2. Installation of sampling system: According to the requirements of HJ 353-2019 and the "Emission Standards for Electroplating Pollutants" (GB 21900-2008), install dedicated anti-corrosion sampling probes in the mainstream area of each monitoring point, ensuring that the probes are submerged and avoid dead corners of water flow; The sampling pipeline adopts PTFE strong acid and alkali resistant hose, and the pipeline laying slope is not less than 1% to avoid the formation of water accumulation bends; Install a dedicated heavy metal filtration pretreatment device (with a pore size of 5 μ m) at the front end of the sampling pipeline, equipped with an automatic backwash function, set to backwash 4 times a day, with a flushing duration of 40 seconds each time, to specifically solve the problem of suspended solids and heavy metal particle blockage in electroplating wastewater.

3. Installation of power supply system: The power supply is provided by the industrial dedicated anti-corrosion power supply line (AC 220V) in the factory area. A dedicated stabilized power supply and leakage protection device are installed. The power supply line is laid through anti-corrosion and explosion-proof sleeves, and the grounding treatment is done well (grounding resistance ≤ 4 Ω) to ensure stable power supply voltage and meet the electrical safety requirements of the corrosive environment in the workshop.
4. Installation of transmission module: Connect the Ethernet+GPRS dual transmission module to the GNST-SC1000 host data interface and fix it in the signal good area inside the station building; Connect to the industrial Ethernet in the factory area and insert an IoT SIM card to ensure a backup transmission channel; Through the Modbus TCP protocol of the device, dual network adaptation is completed with the electroplating plant's environmental protection intelligent control platform and the Meizhou Ecological Environment Bureau supervision platform. The data upload frequency (1h/time) and communication parameters are configured to obtain key information such as MN number required for networking.

（2） Pipeline and line connection

1. Pipeline connection: Connect the sampling probe → heavy metal pretreatment 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 pre-treatment device, and ensure regular automatic backwash effect; The waste liquid recycling pipeline is connected to the wastewater treatment system of the electroplating plant to avoid secondary pollution of heavy metal waste liquid.

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 explosion-proof sleeves, and the sleeve interfaces shall be sealed properly. The routing of the lines shall avoid acid and alkali pipelines and high-temperature equipment; Mark both ends of the line for easy maintenance.

3. Installation of auxiliary systems: Install video surveillance equipment (2-megapixel high-definition infrared cameras) in the monitoring station building to monitor the operation status of equipment and the sampling area of the main exhaust outlet; Install access control system, adopting a dual control mode of card swiping and mechanical lock to ensure the safety of monitoring facilities; The station building is equipped with acid and alkali neutralization waste liquid collection tanks for emergency protection.

4、 Debugging core process

The debugging work strictly follows the requirements of HJ 354-2019 standard and "Emission Standards for Electroplating Pollutants" (GB 21900-2008), combined with the water quality characteristics of electroplating wastewater, and carries out core index debugging 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 Table 2 of the "Emission Standards for Electroplating Pollutants" (GB 21900-2008)).

2. Precise calibration and debugging: In response to the strong interference of heavy metals in electroplating wastewater, a three-point calibration method is used to calibrate each core indicator separately. After cleaning the detection channel with deionized water three times, blank solution, low concentration standard calibration solution, and high concentration standard calibration solution are added in sequence. After the reading stabilizes, 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 chromium and total nickel requires the completion of parameter debugging of the high-temperature digestion module in advance (digestion temperature of 165 ℃, digestion time of 30 minutes) to ensure the digestion of heavy metal ions; Hexavalent chromium calibration requires synchronous debugging of the anti-interference module to avoid interference from other ions in the detection results.

3. Performance testing and debugging: Conduct a 72 hour continuous operation test (in accordance with the debugging requirements of key pollution source online monitoring equipment), 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 wastewater samples from electroplating plants, and the relative error between equipment measurements and laboratory standard methods (atomic absorption spectrophotometry, potassium dichromate 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 scenarios where the concentrations of hexavalent chromium and total nickel exceed the standard, verify the synchronous response between the local alarm (sound and light alarm) of the equipment and the platform alarm function, and require the electroplating plant's environmental protection intelligent control platform and the municipal ecological environment bureau's supervision platform to receive alarm information within 5 minutes; Test the stability of dual transmission channels to ensure a data upload rate of ≥ 99.5%.

Technical briefing: The supplier's technical personnel conducted a special technical briefing on GNST-SC1000 equipment to the operation and maintenance personnel of the electroplating plant, focusing on explaining the daily maintenance points of the equipment for electroplating wastewater (such as cleaning of heavy metal pretreatment devices, replacement of corrosion-resistant pipelines, preparation and replacement of special reagents, and maintenance measures for equipment in corrosive environments), 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 composed of electroplating plants, suppliers, and third-party environmental testing institutions. They compare the installation and commissioning plan with relevant standards to inspect the equipment installation standardization, 72 hour continuous operation stability, core indicator detection performance (indication error, repeatability, drift), data upload accuracy, and alarm function effectiveness. They also synchronously verify the equipment's connection with the supervision platform of the Municipal Ecological Environment Bureau, as well as the operation status of video surveillance and access control systems, to ensure compliance with the acceptance requirements of key pollution source automatic monitoring facilities.

2. Data delivery: After passing the acceptance inspection, the supplier shall deliver a complete set of materials to the electroplating factory, including installation and commissioning reports, equipment manuals, calibration records, 72 hour operation test reports, quality assurance documents, and operation and maintenance manuals suitable for electroplating wastewater monitoring (including targeted maintenance points and common troubleshooting methods), and complete the acceptance data filing as required.

6、 Project effectiveness

Stable operation of equipment: After installation and debugging, the GNST-SC1000 monitoring equipment has achieved stable operation in the highly corrosive and fluctuating water quality conditions of the electroplating plant. The continuous upload rate of core indicator monitoring data is ≥ 99.5%, and the equipment failure rate is less than 1%, which is suitable for long-term monitoring of electroplating wastewater.

Environmental compliance guarantee: The equipment realizes 24-hour continuous monitoring of core indicators of electroplating wastewater, and the data is real-time connected to the intelligent environmental control platform of the electroplating plant and the supervision platform of Meizhou Ecological Environment Bureau, effectively avoiding the risk of excessive heavy metal emissions; Through data anomaly warning, three incidents of fluctuation in wastewater discharge from electroplating workshops were detected and dealt with in advance, ensuring that the effluent quality remained stable and met the standards in Table 2 of the "Emission Standards for Electroplating Pollutants" (GB 21900-2008), 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 of electroplating wastewater, a targeted instrument usage registration system, regular calibration (once a month), and maintenance system have been established. The requirements for equipment inspection in corrosive environments have been clarified, and operation and maintenance personnel have a clear understanding of equipment management responsibilities, effectively reducing the incidence of instrument failures and extending the service life of equipment.

Process optimization support: Based on continuous monitoring data from equipment, the environmental protection department of the electroplating plant analyzes the changes in wastewater quality under different electroplating processes and production loads, providing data support for adjusting wastewater treatment process parameters (such as flocculant dosage and pH adjustment value), achieving precise removal of heavy metals, and reducing wastewater treatment costs by about 9%.

6、 Experience Summary and Prospect

（1） Experience summary

Anti corrosion adaptation is key: This installation and debugging fully combines the strong corrosiveness and high heavy metal content of electroplating wastewater, optimizes the sampling pretreatment plan, equipment anti-corrosion protection measures, and corrosion-resistant accessory selection in a targeted manner, adopts dedicated heavy metal detection modules and anti-interference technology to ensure accurate adaptation of equipment to electroplating plant sewage treatment scenarios, and lays the foundation for data accuracy.

Government enterprise collaboration is a guarantee: the efficient collaboration between electroplating factories and instrument suppliers ensures that installation and commissioning plans are in line with the actual production conditions of the enterprise, while strictly aligning with local ecological environment supervision requirements, ensuring the smooth progress of equipment networking filing; The establishment of a follow-up technical support mechanism provides strong support for solving complex problems in the long-term operation of equipment in corrosive environments, such as heavy metal detection interference and pipeline corrosion.

（2） Future prospects

Based on the installation and commissioning results, the subsequent electroplating plant will further enhance its environmental monitoring capabilities. Firstly, the GNST-SC1000 equipment deployment scope will be expanded, and monitoring points will be added to the drainage outlets of each electroplating workshop to achieve full process water quality monitoring of wastewater generation; Secondly, relying on the advantages of equipment data transmission, we will deepen the linkage analysis between monitoring data and production processes, and combine with the requirements of Meizhou's electroplating industry rectification and improvement to enhance the level of intelligent environmental protection control; The third is to continuously deepen cooperation with suppliers, timely follow up on equipment technology upgrades, optimize monitoring plans in conjunction with new environmental regulations, and provide stronger support for the green and sustainable development of enterprises.