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Monitoring case of sewage treatment plant in Yichun City, Jiangxi Province

Date: 2025-12-24Read: 1

Installation and commissioning case of GNST-SC1000 online COD, ammonia nitrogen, total phosphorus, and total nitrogen detector for sewage treatment plant in Yichun City, Jiangxi Province

1、 Project Background and Overview

（1） Project Background

As an important ecological barrier in the Ganjiang River Basin, Yichun City in Jiangxi Province is responsible for the treatment of urban domestic sewage and some industrial wastewater by its central urban sewage treatment plant. The current treatment capacity is 140000 tons/day, and the effluent is finally discharged into the Yuanhe Yichun Industrial Water Area. The water quality protection target of this water area is Class IV surface water standard. In order to implement the Class A discharge requirements of the "Pollutant Discharge Standards for Urban Sewage Treatment Plants" (GB18918-2002), strengthen the supervision of effluent quality, and improve the digital level of environmental governance, a sewage treatment plant in a central urban area of Yichun City has set up monitoring points at the main discharge outlet and the outlet of the biochemical treatment unit, equipped with GNST-SC1000 online COD ammonia nitrogen total phosphorus total nitrogen detector. This device has the characteristics of IP68 high protection level, high detection accuracy, and strong anti-interference ability. 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 high flow and continuous operation requirements of sewage treatment plants. The installation and commissioning work is led by the technical team of Henan Suijing Environmental Protection Technology Co., Ltd., with the cooperation of the operation and maintenance department of the sewage treatment plant, to ensure accurate equipment docking with the treatment process, guarantee the authenticity and effectiveness of monitoring data, and provide data support for compliant discharge and regional water ecological protection in the factory area.

（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 on-site layout of the GNST-SC1000 detector host, sampling system, preprocessing device, power supply, and GPRS transmission module to ensure 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 comprehensive sewage quality characteristics of the city, precise calibration and performance testing of COD, ammonia nitrogen, total phosphorus, and total nitrogen indicators are 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 high flow sewage monitoring needs.
System linkage: Ensure stable networking between GNST-SC1000 equipment and Yichun Ecological Environment Supervision Platform and Factory Intelligent Control Platform, 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 supervision of key pollution sources.
Long term guarantee: Formulate a standardized installation and commissioning manual and operation and maintenance points for GNST-SC1000 model that is suitable for the working conditions of sewage treatment plants, providing technical support for the long-term stable operation of equipment and environmental compliance management in the factory area.

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 organization: Clean up debris on the installation site, construct standardized monitoring stations at monitoring points, ensure good ventilation and controllable temperature and humidity (temperature 5-40 ℃, relative humidity ≤ 85% RH), and level the equipment installation base; Excavate the cable trench according to the design path, carry out waterproof and anti-seepage treatment, seal the cable trench cover to prevent sewage leakage and pollution.
Safety protection: Set up construction warning signs, equip with safety helmets, insulated gloves, waterproof shoes and other protective equipment; Check the insulation performance of construction tools, develop emergency shutdown plans for rainy days, and strengthen electrical safety protection for high humidity environments in the factory area.

Refinement of the plan: The technical team communicated with the person in charge of the operation and maintenance of the sewage treatment plant in advance, combined with the characteristics of large urban comprehensive sewage volume and relatively stable water quality but fluctuating suspended solids content, to refine the installation and commissioning plan in a targeted manner, focusing on clarifying the operation standards of key links such as the installation and fixing method of GNST-SC1000 host, the selection of filtration accuracy for pre-treatment devices, and the connection parameters between data and the municipal ecological environment supervision platform, to ensure that the plan meets the actual operational needs of the 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 in the standardized monitoring station building, 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 sealing components to avoid the high humidity environment inside the station building affecting equipment operation.

2. Installation of sampling system: According to HJ 353-2019 requirements, install the sampling probe in the main flow area of the main 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 flow pre filtration device (with a pore size of 5 μ m) to specifically solve the problem of suspended solids blockage in sewage. The filtration device is equipped with an automatic backwash function, set to backwash twice a day for easy maintenance and cleaning.

3. Installation of power supply system: The industrial power supply (AC 220V) in the factory area 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 high-power equipment in the factory area that may affect instrument operation; The power supply line is laid with waterproof conduit and properly grounded to ensure electrical safety.
4. Installation of transmission module: Connect the GPRS transmission module to the GNST-SC1000 host data interface and fix it in a well signal area inside the station building; Insert the IoT SIM card, test the signal strength (ensure ≥ 3 grids), complete dual network adaptation with the smart control platform of the sewage treatment plant and the ecological environment supervision platform of Yichun City through the device Modbus TCP protocol, configure the data upload frequency (1h/time) and communication parameters, and obtain key information such as MN number required for networking.

（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 factory's sewage treatment system to avoid secondary pollution.

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 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 high flow and continuous operation of sewage treatment plants. 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 Class A standard of "Pollutant Discharge Standards for Urban Sewage Treatment Plants" (GB18918-2002)).

2. Precise calibration and debugging: The two-point calibration method is used to calibrate the four indicators separately. After cleaning the detection channel with deionized water three times, blank solution and 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 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 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%; Compare and test the actual sewage samples in the factory area, and ensure the accuracy of the data by comparing the equipment measurement values with the laboratory standard method measurement values with a relative error of ≤± 15%.
4. System linkage debugging: Test the linkage performance of the entire process of automatic sampling, preprocessing, detection, and data upload; Simulate the scenario of COD and ammonia nitrogen concentration exceeding the standard, verify the synchronous response of local alarm and platform alarm functions of the equipment, and require that both the intelligent control platform of the sewage treatment plant and the municipal ecological environment 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 operation and maintenance personnel of the sewage treatment plant, focusing on explaining the daily maintenance points of the equipment for urban comprehensive sewage (such as adjusting the backwash cycle of the pre filtration device, cleaning methods for the detection channel, and reagent replacement standards), 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 sewage treatment plant, 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, four indicators testing performance (indication error, repeatability, drift), data upload accuracy, and alarm function effectiveness. They also synchronously verify the connection between the equipment and the municipal ecological environment supervision platform 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 sewage treatment plant, 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 troubleshooting methods) that are suitable for the sewage treatment plant. The acceptance data shall be filed as required.

6、 Project effectiveness

Stable Equipment Operation: After installation and debugging, the GNST-SC1000 detector has achieved stable operation under high flow and continuous operation conditions 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%, which is suitable for urban comprehensive sewage monitoring needs.

Environmental compliance guarantee: The equipment achieves 24-hour continuous monitoring of the core indicators of effluent, and the data is real-time connected to the intelligent control platform of the sewage treatment plant and the ecological environment supervision platform of Yichun City, effectively avoiding the risk of exceeding environmental standards; Through data anomaly warning, three incidents of biochemical treatment process fluctuations were detected and dealt with in advance, ensuring that the effluent quality remained stable and met the Class A standard of the "Pollutant Discharge Standards for Urban Sewage Treatment Plants" (GB18918-2002), providing strong support for the ecological protection of the Yuanhe River water area.

Operation and Maintenance Management Standards: Based on the characteristics of GNST-SC1000 equipment and the monitoring requirements of sewage treatment plants, 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 occurrence rate of instrument failures and extending the service life of the equipment.

Process optimization support: Based on continuous monitoring data from equipment, the operation and maintenance department of the sewage treatment plant analyzes the changes in sewage quality at different time periods, providing data support for adjusting biochemical treatment process parameters, achieving precise dosing of chemicals, and reducing sewage treatment costs by about 6%.

6、 Experience Summary and Prospect

（1） Experience summary

Adaptation to working conditions is key: This installation and commissioning fully combines the characteristics of high flow, continuous operation, and fluctuation of suspended solids in sewage treatment plants. Targeted optimization of sampling pretreatment schemes and equipment installation protection measures are carried out, and suitable corrosion-resistant pipelines and filtration devices are selected to ensure accurate adaptation of equipment to the operating conditions in the factory area, laying the foundation for data accuracy.

Government enterprise collaboration is a guarantee: the efficient collaboration between sewage treatment plants and instrument suppliers ensures that installation and commissioning plans are in line with the actual working conditions of the plant area, 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.

（2） Future prospects

The subsequent sewage treatment plant will further enhance its environmental monitoring capabilities based on the installation and commissioning results: firstly, expand the deployment range of GNST-SC1000 equipment, add monitoring points in the pretreatment unit, and achieve water quality monitoring throughout the entire sewage treatment process; Secondly, relying on the advantages of device data transmission, we will deepen the linkage analysis between monitoring data and processing technology, and improve the level of intelligent control in accordance with the requirements of the integrated construction of environmental supervision in Yichun City; Thirdly, we will continue to 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 regional water ecological protection and green development.