CONSTRUCTION OF AUTOMATIC WATER LEVEL CONTROL

SYSTEM USING A FLOAT SWITCH

BY

DANIEL IKPOKO ENOS

CMA/021/ND/ME/006

HAYFORD OWAJI-OKANUNYE JAMES

CMA/021/ND/ME/002

VINCENT OHAZURUME BOHAM

CMA/021/ND/ME/011

DEPARTMENT OF MARINE ENGINEERING,

CHARKIN MARITIME ACADEMY,

PORT HARCOURT,

RIVERS STATE.

AUGUST, 2023
CONSTRUCTION OF AUTOMATIC WATER LEVEL CONTROL
SYSTEM USING A FLOAT SWITCH

BY

DANIEL IKPOKO ENOS

CMA/021/ND/ME/006

HAYFORD OWAJI-OKANUNYE JAMES

CMA/021/ND/ME/002

VINCENT OHAZURUME BOHAM

CMA/021/ND/ME/011

BEING A PROJECT SUMITTED TO:

DEPARTMENT OF MARINE ENGINEERING,

CHARKIN MARITIME ACADEMY,

PORT HARCOURT,

RIVERS STATE.

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF NATIONAL DIPLOMA IN MARINE ENGINEERING

AUGUST, 2023

i
 CERTIFICATION

This is to certify that this project “Construction of an automatic water level

control system using float switch” was carried out by Daniel Ikpoko Enos,
Hayford Owaji-Okanunye James, Vincent Ohazurume Boham and submitted to
the department of Marine Engineering, Charkin Maritime Academy, Port
Harcourt, Rivers State. For the award of National Diploma in Marine
Engineering.

The construction has been under the supervision of Engr. Benson S. Inyang and
Engr. Sam Ogunmokun and has been duly approved.

______________________ ______________________

Engr. Sam Ogunmokun Date

Engr. Benson S. Inyang

Project Supervisors

______________________ ______________________

Engr. Maurice N. Ijeoma Date

Head of Department

______________________ ______________________

External Examiner Date

ii
 DECLARATION

We, Daniel Ikpoko Enos, Hayford Owaji-Okanunye James, Vincent

Ohazurume Boham, certify that this project is our own work, based on our
personal study and/or research and that we have acknowledged all material and
sources used in its preparation, whether they be books, articles, reports, lecture
notes, and any other kind of document, electronic or personal communication.

We also certify that this project has not previously been submitted for assessment
in any academic capacity, and that we have not plagiarised the work of other
persons.

_______________________ Date_____________

Daniel Ikpoko Enos

_______________________ Date_____________

Hayford Owaji-Okanunye James

_______________________ Date_____________

Vincent Ohazurume Boham

iii
 ACKNOWLEDGEMENT

We would like to express our heartfelt gratitude to all those who contributed to
the successful completion of our final year group project. This project would not
have been possible without the combined efforts, dedication, and commitment of
each team member. We extend our sincere appreciation to our project supervisors
for their invaluable guidance, unwavering support, and insightful feedback
throughout this journey. Your expertise and encouragement have been
instrumental in shaping our project into what it is today.

We are also grateful to our fellow students and peers who provided us with
valuable insights, suggestions, and constructive criticism, which greatly enriched
our project's quality and depth.

Special thanks go to our families and friends for their continuous understanding,
encouragement, and patience during this demanding phase of our academic
journey.

Lastly, we acknowledge the resources, facilities, and assistance provided by our

school, Charkin Maritime Academy and our Sponsors – Andoni LGA and
Obio/Akpor LGA respectively that enabled us to conduct our research and
execute our project effectively.

With sincere appreciation for all those who contributed to this endeavor, we
present our final year group project as a testament to teamwork, collaboration,
and the pursuit of knowledge.

iv
 DEDICATION

This project is dedicated to the Almighty God for his love and infinite mercies
and to the overwhelming knowledge, wisdom, vision and understanding he has
bestowed upon us.

v
 ABSTRACT

This paper presents the construction of an automatic water level control system
using float switch aimed at providing appropriate control to pump water to an
overhead tank when it is empty and automatically stopping the pump when the
tank is full. The system incorporates a contactor, circuit breaker and a float
switch that are energized to provide a direct online start of the motor. A float
switch uses the Archimedes principle of flotation to provide the electrical
contact to switch the supply ON or OFF to the motor when the tank is empty or
full, respectively. This system is capable of seamlessly utilizing water at
domestic and industrial levels without causing overflow and without human
intervention.

vi
 TABLE OF CONTENTS

Title Page i

Certification ii

Declaration iii

Acknowledgement iv

Dedication v

Abstract vi

Table of Contents vii

List of Figures x

Chapter One

Introduction

1.1 Background 1

1.2 Statement of Problem 2

1.3 Aim of project 3

1.4 Objective of project 3

1.5 Significance of the study 3

1.6 Scope of the study 5

1.7 Description of the study area 5

1.8 Study Plan 6

Chapter Two

Literature Review

vii
2.1 Introduction 8

2.2 Conceptual review 9

2.3 Theoretical framework 9

2.4 Empirical review 9

Chapter Three

3.1 Methodology 11

3.2 Description and layout of component parts of the system 12

3.2.1 Contactor 12

3.2.2 Circuit breaker 13

3.2.3 Float switch 14

3.3 Fabrication process of a model tank 15

3.3.1 Plate cutting 15

3.3.2 Filing 15

3.3.3 Drilling 16

3.3.4 Welding 17

3.3.5 Grinding 18

3.3.6 Testing for leakages 18

3.3.7 Painting 19

3.4 The connection process 19

3.5 Result 21

3.6 Maintenance 22

viii
3.7 Calculations and choice of components 23

3.7.1 Design Analysis 23

3.7.2 Preliminary Test 24

Chapter Four

4.1 System Performance 26

4.2 Limitations of the Project 26

4.3 Discussion 26

Chapter Five

5.1 Summary of Findings 29

5.2 Recommendation 29

5.3 Conclusion 30

References 31

ix
 LIST OF FIGURES

Fig 1.1 The map of rivers state, nigeria 6

Fig 3.1 Circuit diagram 12

Fig 3.2a Electrical symbol of contactor 12

Fig 3.2b Pictorial symbol of contactor 13

Fig 3.3a Electrical symbol of circuit breaker 13

Fig 3.3b Pictorial symbol of circuit breaker 13

Fig 3.4a Electrical symbol of float switch 14

Fig 3.4b Pictorial symbol of float switch 14

Fig 3.5a The diagram of the marked-out plate 15

Fig 3.5b The plate cutting process 15

Fig 3.6 The filing process 16

Fig 3.7 The drilling process 16

Fig 3.8a design of a model tank 17

Fig 3.8b the welding process 17

Fig 3.9 The grinding process 18

Fig 3.10 completion of the model tank 19

Fig 3.11 Block diagram of a water level controller 20

Fig 3.12a the interior view of completed work (prototype of automatic
21
water level control system)
Fig 3.12b the finished work with the model tank attached to the system 21

Fig 3.13 Figure showing the high water level and indicator response 24

Fig 3.14 figure showing low water level and indicator display 25

Fig 3.15 the interior view of the control system without the tank 25

x
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND

Water is one of the basic needs of man (male and female), animals and plants and
also for the economic development of a nation. Many functions necessary to
domestic and industrial homes grind to halt when water supply from utility
corporation, bore holes stop. The availability of water in domestic, commercial
homes and on-board ships result in high productivity, clean environment and
further constitute healthy living of the people.

In these modern times, the dependency on water is so much that it has become an
aspect of people’s way of life. The ever-increasing demand for water for domestic
and industrial purposes necessitate providing bulk water supply to meet the
demand of the consumers. This is achieved through the help of suitable water
tank to preserve enough water for daily use. The expectation of the people is that
water tanks and its control mechanism should function efficiently to deliver water
when the demand is necessary. Tank is a container which holds liquid or gas, for
instance water, fuel, petrol (Patrick, 2003).

Automatic water tank control mechanism could be in the form of mechanical,

electrical or in solid state (electronic). Therefore, its uses depend on the
environment and the people to use it. Automatic Water Tank Control Mechanism
(AWTCM) has two important set points, the minimum and the maximum and
operates on the principle that when the water level in the tank is at the minimum
level, the pump will start to raise the water to a maximum level and cut off
automatically. This automatic control device is installed inside the tank by a
competent technician to monitor the water level.

The major components of automatic water level control system using a float
switch includes;

A contactor is an electrically controlled switch that is used for making and

breaking the power supply to heavy-load motors and other electrical equipment.

1
Contactors typically have power contacts, auxiliary contacts, and a coil that
provides the control voltage. When the coil is energized, the power contacts close,
and when the coil is de-energized, the power contacts open, interrupting the
power flow (Herman, 2017).

A circuit breaker is an automatically operated electrical switch designed to protect

an electrical circuit from damage caused by overcurrent, typically resulting from
an overload or a short circuit. It functions as a disconnect switch that can be
manually operated to open the circuit, as well as automatically trip and interrupt
the current flow when an abnormal condition is detected. Circuit breakers provide
a higher level of safety compared to fuses, as they can be reset after tripping,
restoring power to the circuit once the fault is resolved. (Mullin & Simmons,
2017).

A float switch is an electrical device that is used to detect the level of liquid within
a container. It consists of a buoyant float connected to an electrical switch
mechanism. As the liquid level rises or falls, the float moves correspondingly,
activating or deactivating the switch. Float switches are commonly used in
applications such as controlling water levels in tanks, monitoring sump pump
operation, or preventing overflow in industrial processes. (Scherz & Monk,
2016).

Lack of or insufficient water supply makes it very difficult for the consumers to
satisfy the needs. This means that domestic and industrial activities will collapse.
In the light of the underlying background information, this project is aimed at the
construction of an automatic water level controller for domestic and industrial use
in Rivers State.

1.2 STATEMENT OF THE PROBLEM

Water is one of the indispensable liquids to life, it promotes human comfort and
clean environment. This means that lack or absence of water is a disease to human
being that has the potential to cause sickness and death. Though there is water in

2
the air and also in the ground, it does not sustain human life. In this circumference,
most domestic, commercial, and industrial organization drain water from the
ground by the use of submersible water pump and further preserved this water in
a tank for daily use. It is observed that most of the times, the pump that feeds the
water tank do overfill it, because there is no automatic mechanism to stop it. This
itself constitutes not only waste of water and electrical energy, it is
mismanagement of natural resources and an eyesore in the environment.

In consideration of these problems that rendered management of water in

domestic, commercial and industrial organization ineffective, the designers
become interested in the design and construction of automatic water level
controller that can start and stop the water pump when it is appropriate.

1.3 AIM OF THE PROJECT

The aim of this project is to construct an Automatic Water Level Control System
using Float Switch.

1.4 OBJECTIVE OF THE PROJECT

Specifically, the objectives of this construction include;

i. To determine the component parts of an automatic water level control

system
ii. The layout of components for the automatic water level control system
iii. The connections of component parts
iv. The maintenance of the system and its component parts

1.5 SIGNIFICANCE OF THE STUDY

This project; the Construction of an Automatic Water Level Control System using
a Float Switch shall be of several significant benefits to hospitals, schools, hotels,
ships, students and project designers.
3
The project shall be of great benefit to hospitals as hospital uses water in various
ways to ensure proper hygiene, sanitation and patient care. Therefore, if this
project is put into use it will provide a more efficient water management and
ensure availability of water for drinking, hand washing, cleaning and disinfection,
laundry services and medical equipment such as dialysis machine, dental tools
and sterilization system.

Schools on the other hand, shall benefit from this project particularly as water is
being used in various ways and in different offices to ensure proper hygiene, the
automatic water level control system not only minimizes the risk of water tank
overflow, but also reduces cost of maintenance efforts and potential damage to
the school infrastructure. The system also helps in efficient water management,
reducing water wastage and resulting in cost savings on water bills of the schools.
Without an automated water system, manual monitoring and control of water
levels can be time consuming and may require regular staff intervention. But by
automating the process schools can allocate resources more efficiently, save staffs
time and reduce need for manual labour.

Ships shall benefit extensively from this project as there are several water/fluid
tanks onboard ships which will need to be fitted with an automatic water level
control system to bring about responsible water/fluid management by optimizing
usage aligning with sustainability goals.

Students shall also benefit from this project as the availability of a notable project
work gives students guidance and a reference to fall back on when they are about
embarking on their own projects. To us, as project designers, we shall also benefit
from this project especially when student uses our project as a source of material
in their own research works, citations will be made for every of our intellectual
content.

4
1.6 SCOPE OF THE STUDY

This project limits to the construction of an automatic water level control system
using a float switch. It further limits to the layout, connections and maintenance
of the system.

1.7 DESCRIPTION OF STUDY AREA

The study area for this project is Rivers State, Nigeria. Rivers State is one of the
states in the Niger Delta region of Southern Nigeria, created in 1967 out of the
former Eastern Region. Rivers State share boundaries with Imo to the North, Abia
and Akwa Ibom to the East, Atlantic Ocean to the South, and Bayelsa and Delta
to the West. It covers an area of approximately 11,077 square kilometers (4,277
square miles). The capital city of Rivers State is Port Harcourt, considered to be
the commercial center of the Nigerian oil industry.

With a population of 5,198,716 as of the 2006 census, Rivers State is the 6th most
populous state in Nigeria. Rivers State is a diverse state that is home to many
ethnic groups: Ikwerre, Ogoni, Abua, Andoni and the Ijaws. The state is
particularly noted for its linguistic diversity, with 28 indigenous languages being
said to be spoken in Rivers State, these include Ikwerre, Abua, Ogoni, Obolo and
the Ijaw languages. Rivers State is the 26th largest state by area, and its geography
is dominated by the numerous rivers that flow through it, including the Bonny
River.

Economically, Rivers State is dominated by the state's booming petroleum

industry, domestic and commercial building e.g. schools, universities, hospitals
and hotels. (Wikipedia, 2023)

5
Fig 1.1 The map of Rivers State, Nigeria

1.8 STUDY PLAN

The various stages involved in the development of this project have been properly
put into four chapters to enhance comprehensive and concise reading.

In this project thesis, the project is organized sequentially as follows:

Chapter one of this work is on the introduction to automatic water level control
system. In this chapter, the background, significance, objective, limitation and
problem of automatic water level control system were discussed.

6
Chapter two is on literature review of automatic water level control system. In
this chapter, all the literature pertaining to this work was reviewed.

Chapter three is on design methodology. In this chapter all the method involved
during the construction of the system and the fabrication and construction of the
model tank used were discussed.

Chapter four is on system performance, limitations of the project and discussion.

Chapter five is on summary, conclusion, recommendation and references.

7
 CHAPTER TWO

LITERATURE REVIEW

2.1 INTRODUCTION

The automatic water level control system using a float switch is a system designed
to continuously monitor and control the water level present in the tank. It uses a
float switch equipped with magnetic sensors which detects difference in the
tank’s water level. The water level control system is used to turn on and off
pumps, thereby preventing possible overflow.

However, there are so many bodies of researchers, examining various aspects of

automated water level control systems. Wayner and Poqqu (2008) proposed a
novel approach for automatic water level control based on the use of a genetic
algorithm to determine the optimal settings for the different components of the
system. The authors tested the proposed system in a number of water reservoirs
and found that it was effective in controlling the water level with minimal manual
intervention.

An important study by Shah Moradi and Hossein Zadeh (2010) investigated the
design and performance of a fuzzy logic-based automatic water level control
system in two irrigation canals in the Fars Province of Iran. The authors found
that the system was able to significantly reduce irrigation losses due to overflow
and effectively maintain the desired water level in the canals.

Also, Ghasem Zadeh et al. (2012) developed an automated water level monitoring
and control system based on a neural network-fuzzy logic approach. The authors
reported that the system was able to accurately detect and maintain the desired
water level, with an average absolute error of less than 0.1 m, which is
significantly better than other existing water management systems.

Finally, Chen et al. (2015) demonstrated the performance of an autonomous water

level control system, based on the fuzzy-PID approach, that was implemented in
a large wetland in southern China. The authors reported that the system was
effective in controlling the fluctuations of the water level, and they suggested that

8
such systems could be a valuable tool for future water resources management in
coastal wetlands.

2.2 CONCEPTUAL REVIEW

The main concept behind using a float switch for water level control is based on
the principle of buoyancy. A float switch is basically a buoyant object which is
connected with a sensing circuit. Float switches, which are generally suspended
on the water surface, are triggered when the water level reaches their pre-set limits
and activate the pump accordingly with the help of a contactor. When the water
level rises, the buoyant object will float and activate the sensor which would then
send a signal to activate pumps to regulate the water level. The concept has been
used for decades to control the water level between a range of different conditions
and scenarios.

2.3 THEORETICAL FRAMEWORK

The theoretical framework for the automatic water level control system using a
float switch mainly involves the study of buoyancy. Specifically, the principles
of Archimedes’ law are used to study and analyze the behavior of the system
when the water levels change. The buoyancy forces, mass, and mass distribution
of the float switch need to be calculated and optimized in order to provide the
best and most accurate performance.

2.4 EMPIRICAL REVIEW

An empirical review of the automatic water level control system using a float
switch has shown that the system can be used to maintain a constant water level
in a body of water in the tank. The system can also be programmed to specifically
control the water level in the range of certain conditions and optimize the water

9
conservation measures. The application of the system has also been tested in
different bodies of water such as overhead tanks and has been proven to be
effective in controlling and regulating the water levels in these bodies of water.

10
 CHAPTER THREE

3.1 METHODOLOGY

There are various approaches to creating an automatic water level control system
using switching devices; however, most of these methodologies rely on human
intervention. In this particular project, an automatic water level control system is
devised for both overhead and underground tanks. The innovation lies in the
utilization of float switches instead of electronic sensors or other electronic
switching devices. The system's objective is to replenish the water levels without
necessitating human involvement.

The system's architecture is thoughtfully structured to initiate water refills

whenever the water level drops below a specified threshold. Furthermore, the
system is intelligently programmed to deactivate the water pump automatically
as soon as the tank reaches its capacity, thereby preventing overflow. The
methodology employed in this endeavor adopts a modular design approach.

The system's foundation is built upon functional blocks, as showcased in the

subsequent block diagram. Within this framework, the circuit is configured to
discern distinct water levels through the use of float switch, which carefully
monitor the water influx into the tank. Nevertheless, the display capacity can be
expanded or contracted according to the desired level of precision. This can be
accomplished by adjusting the level and position of the float switch in the tank.

To effectively run this system, power flows from the source to the circuit breaker,
guarding against overloads. It then passes through a contactor, an electrical switch
that permits controlled transmission. Moving onward, the power reaches a float
switch, responsible for monitoring liquid levels. Upon activation due to a level
change, the float switch generates a feedback signal. This signal retraces its path
back through the circuit, ultimately reaching the contactor once again. This
feedback triggers the contactor's response, completing the cycle in this controlled
circuit arrangement. The ultimate embodiment of this methodology is visually
represented in the comprehensive circuit diagram provided below.

11
Fig 3.1 Circuit Diagram

3.2 DESCRIPTION AND LAYOUT OF COMPONENT PARTS OF THE

SYSTEM

3.2.1 CONTACTOR

A contactor (Fig 3.2) is an electrical device used to control and switch high-power
circuits. It consists of contacts controlled by an electromagnet, enabling the flow
or interruption of electrical current to loads such as motors or heating systems.
Contactors are commonly used in industrial settings for remote or automatic
control of electrical devices. They provide reliable and durable switching
capability for efficient power control.

Fig 3.2a Electrical symbol of contactor

12
 Fig 3.2b Pictorial symbol of contactor

3.2.2 CIRCUIT BREAKER

A circuit breaker (Fig 3.3) is a protective device that automatically interrupts the
flow of electrical current in a circuit when there is an overload or a fault. Its main
purpose is to prevent damage to electrical equipment and minimize the risk of
electrical fires. When a circuit breaker detects excessive current, it trips and opens
the circuit, effectively stopping the flow of electricity. Once the issue is resolved,
the circuit breaker can be reset to restore power.

Fig 3.3a Electrical symbol of circuit breaker

Fig 3.3b Pictorial symbol of circuit breaker

13
3.2.3 FLOAT SWITCH

A float switch (Fig 3.4) is a device that detects liquid levels and controls the
operation of a pump, valve, or other electrical equipment based on those levels.
It consists of a float attached to a lever or arm that moves with the liquid level.
When the liquid rises or falls to a certain point, the float switch triggers a switch
mechanism, either opening or closing an electrical circuit. Float switches are
commonly used in applications such as sump pumps, sewage systems, and water
tanks to regulate liquid levels and automate control actions.

Fig 3.4a Electrical Symbol of float switch

Fig 3.4b Pictorial Symbol of float switch

14
3.3 FABRICATION PROCESS OF A MODEL TANK

3.3.1 PLATE CUTTING

The plate cutting involves the use of a cutting disc attached to a handheld
cutting machine. First the steel pate was carefully measured and marked out
with a dimension of 14x12inch.

Fig 3.5a the diagram of the marked-out plate

Fig 3.5b the plate cutting process

3.3.2 FILING

The filing involves the use of wired brushes attached to a handheld machine and
used to file and smoothen the plate surfaces before welding.

15
Fig 3.6 The filing process

3.3.3 DRILLING

In this phase the water outlet from the tank was marked and drilled with an
internal diameter of ∅20𝑚𝑚 as well as the passage of the float switch from the
control unit into the tank with a diameter of ∅10𝑚𝑚. This was achieved using a
drilling machine and a drill bit of ∅10𝑚𝑚 and ∅20𝑚𝑚 respectively.

Fig 3.7 The Drilling Process

16
3.3.4 WELDING

The welding process involves the use of arc welding machine to join the various
parts of the metals together to form a model tank.

Fig 3.8a design of a model tank

Fig 3.8b the welding process

17
3.3.5 GRINDING

This process involves the use of a grinding disc attached to a portable hand
grinding machine used for smoothening, levelling and giving a finishing touch
to the welding part of the tank in other to have a fine surface area.

Fig 3.9 The grinding process

3.3.6 TESTING FOR LEAKAGES

The tank was subjected to watertight integrity test. The essence is to look out
for possible leakages by pouring water into the tank and left for a duration of
about 10 minutes before finally painted.

18
3.3.7 PAINTING

After successful completion of the tank, the model tank was painted.

Fig 3.10 completion of the model tank

3.4 THE CONNECTION PROCESS

To connect the automatic water level control system using float switch, below
are the steps involved:

1. The positive and the negative terminal of the circuit breaker inlet is
connected to the power source.

2. The positive and negative terminal of the circuit breaker outlet is

connected to the L1 and L2 terminal of the contactor inlet respectively.

3. The L1 terminal of the contactor inlet is looped to the A1 of the contactor

coil.

4. The L1 and L2 terminal of the contactor outlet is connected to the load;

the motor and the indicator lamp.
19
5. The ‘common’ of the float switch is connected to the negative terminal of
the contactor inlet.

6. The ‘normally close, NC’ wire of the float switch is connected to the A2
of the contactor coil.

7. The float switch is placed at the desirable level in the water tank.

Fig 3.11 Block diagram of a water level controller

20
3.5 RESULT

In the final stage of our project, we have successfully completed the

implementation phase and here is the visual representation of the finished work
through a pictorial diagram. This diagram captures the key components,
processes, and interactions that constitute our project's end result.

Fig 3.12a the interior view of Completed work (Prototype of Automatic

water level control system)

Fig 3.12b the finished work with the model tank attached to the control
system

21
3.6 MAINTENANCE

Maintaining an automatic water level control system using a float switch

involves regular checks, cleaning, and occasional adjustments. Here are some
steps to help maintain the system effectively:

1. Regular Inspection: Schedule routine inspections to ensure everything is

functioning correctly. Check for any signs of wear and tear or damage to
the float switch and associated components.
2. Cleaning: Clean the float switch and its surroundings regularly to prevent
any debris or buildup that might interfere with its operation. Make sure
the float can move freely without any obstructions.
3. Testing: Periodically test the float switch to verify its proper
functionality. You can do this by manually raising and lowering the float
to see if it triggers the water level control as expected.
4. Adjustment: If you notice that the water level control is not operating
accurately (e.g., not turning off the water when it should), you may need
to adjust the float switch settings. Follow the manufacturer's instructions
for making adjustments.
5. Periodic Wire Inspection: Inspect the connecting cables or wire
periodically to ensure continuity and to avoid current leakage and open
circuit.

Remember, safety is crucial when working with water and electrical

components. Always disconnect the power supply before conducting any
maintenance or adjustments on the system. If you're unsure about handling
specific aspects of the maintenance, don't hesitate to seek assistance from a
qualified professional.

22
3.7 CALCULATIONS AND CHOICE OF COMPONENTS

3.7.1 DESIGN ANALYSIS

If we consider a borehole depth of 250m, a single phase, 1.5h.p (horse power)

pump motor was chosen. This was found to be suitable for pumping water from
such depth (the depth of a borehole is proportional to the horse power of the
motor). The operating voltage of the motor is 240V a.c. The current capacity of
the motor was calculated with the formula:

P = VI Cos∅ …………………………… (1)

Where P = Power rating of the Induction motor =1.5 h.p = 746 x 1.5 watts

V = Operating voltage = 240v

I = Current rating

Cos∅ = Power factor = 0.8

Calculating for I we obtained

𝑃
I=
𝑉𝑐𝑜𝑠∅

746 𝑥 1.5
I=
240 𝑥 0.8

I = 5.82A ~ 6A (Design current)

If the size of cable required to connect the motor to the power supply was chosen
to be 4mm². Assuming the choice was based on the distance of 25 meters from
the motor to the supply point and the voltage drop per ampere per meter from the
IEE table of current carrying capacity and associated voltage drops (Theraja et al.
2002).

The circuit breaker was connected directly to the main a.c. source. The current
rating of the circuit breaker was 1.45 x the design current (current drawn by
motor).

Icb = 1.45 x 6 = 8.7

23
Therefore, preferred value of the circuit breaker was 10A.

Electromechanical contactor was used to switch ON and OFF the load from the
supply. The load in this case was the pumping machine. This is because it is
usually rated to handle starting and any transient Load current.

The choice of contactor was determined by the power rating of the motor since it
is the contactor that will carry the load current to the motor (direct online starter).
From previous calculation a current of approximately 6A will flow through the
terminals of the contactor when the motor is running. Consequently, a three-pole
contactor of 24A was chosen to allow for transient effect.

3.7.2 PRELIMINARY TEST

A preliminary test was performed; in the first test, an energy bulb is used as shown
in Fig 3.13 below. When the connections are completed and water is manually
poured into the tank, a certain pre-determined level is reached and the bulb light
which was originally ON now goes OFF.

When the tap is open and water level receded in the tank, at a certain fixed level
the bulb light comes ON as shown in Fig 3.14 below. This clearly shows that by
replacing the bulb with pump similar ON and OFF actions will be initiated. This
led to the final design shown in Fig 3.15 below.

Fig 3.13 Figure showing the high water level and indicator response

24
Fig 3.14 figure showing low water level and indicator display

Fig 3.15 the interior view of the control system without the tank

25
 CHAPTER FOUR

4.1 SYSTEM PERFORMANCE

In the preliminary tests, it was determined that the automatic water level control
system using a float switch, effectively regulated water levels in the tank. When
the water level dropped below the predetermined threshold, the float switch
activated the contactor coil, illuminating the light bulb to signify the pumping of
water into the tank. This continued until the float switch detected the desired
level, at which point the light bulb turned off. The system demonstrated consistent
and dependable operation, maintaining the water level within a narrow range. The
addition of an indicator lamp offered a distinct visual clue of the system's actions,
thereby enhancing its usability and monitoring.

4.2 LIMITATIONS OF THE PROJECT

Despite its success, the system exhibited a few limitations that warrant
consideration. Calibration of the float switch was crucial for accurate
performance; slight deviations could lead to improper control actions.
Mechanical wear and tear, mainly in the float switch's moving parts, could
potentially affect its reliability over extended periods.

Electrical disruptions, such as power fluctuations or outages, were observed to

momentarily affect the system's operation, underscoring the need for a backup
power solution for critical applications.

4.3 DISCUSSION

This Project describes the development of an automatic water level control

system that employs a float switch to regulate water levels within a tank. The
system aims to automate the process of maintaining a consistent water level
without requiring constant monitoring or manual adjustments. This kind of

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system finds practical applications in various scenarios, such as filling water
tanks in residential, industrial, or agricultural settings and even onboard ships.

The core principle of the system involves utilizing a float switch as a sensor for
water levels. The float switch is strategically positioned within the tank, and its
internal mechanism is designed to respond to changes in water height. As the
water level shifts, the float switch's position changes as well. When the water
level falls below a predetermined point, the float switch triggers the system for
effective response.

The system comprises of several interconnected components, including a circuit

breaker, a contactor, a motor, an indicator lamp, and float switch. The circuit
breaker serves as a safety device, regulating the power supply to the system. The
contactor acts as a switch that controls the motor and indicator lamp. The float
switch, which consists of electromagnets, its common, normally open, and
normally closed terminals, plays a pivotal role in initiating the automatic
responses.

In operation, when the water level drops and the float switch detects this change,
the float switch's state alters, completing a circuit. This circuit completion
energizes the contactor, which subsequently activates the motor responsible for
pumping water into the tank. Simultaneously, the indicator lamp lights up,
providing a visual indication of the system's operation. As the water level rises
and the float switch reverts to its original state, the circuit is broken, causing the
contactor to deactivate the motor and turn off the indicator lamp.

This cyclical process allows the system to effectively regulate water levels. As
the water level fluctuates due to usage or environmental factors, the float switch
continuously signals the control unit to turn the motor on or off, ensuring that the
desired water level is consistently maintained. By replacing the manual task of
monitoring and adjusting water levels, this system not only saves time and effort
but also prevents potential issues such as overflows.

In essence, the automatic water level control system presents an elegant solution
for managing water levels in a tank through the clever utilization of a float switch
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and an interconnected network of electrical components. It demonstrates how
simple, yet ingenious engineering can lead to efficient automation, benefiting a
wide range of contexts where water management is essential.

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 CHAPTER FIVE

5.1 SUMMARY OF FINDINGS

The "Automatic Water Level Control System using Float Switch" project
emerges as a groundbreaking solution to one of the most pressing challenges in
water resource management. The concept revolves around harnessing the power
of modern technology, specifically float switches and microcontrollers, to
revolutionize how we manage water levels in tanks. The core objective of the
project is to address the wastefulness of water due to overflow incidents and the
inconvenience associated with manual monitoring and control. By seamlessly
integrating innovative hardware and intelligent software, the project strives to
establish a paradigm shift in water conservation and user convenience.

Float switches, positioned at strategic levels within the water tanks, play a pivotal
role in this system. They act as sentinel agents, diligently detecting water levels
and transmitting data to a controller unit. This controller unit acts as the system's
brain, processing the incoming data and orchestrating the necessary actions.
Depending on the water level data received, the controller unit dynamically
regulates the energizing and de-energizing of the pump, ensuring that the water
level remains within the desired range. This, not only mitigates the wastage
caused by overflows but also elevates the water management process to a realm
of automation that is stress free.

5.2 RECOMMENDATION

We recommend this device to private individuals Government and cooperate

organization where there is a need for large consumption of water and the demand
for a neat and hygiene environment free from water pollution.

We also recommend that government should set up industries for local production
of basic electronic component and research centers to be established in schools
to enable young and talented student, graduates have good and sound practical
knowledge on electrical and electronic component as well as their operation. This

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will help in solving some problems in the society and also make life comfortable
for man.

5.3 CONCLUSION

In the culmination of the "Automatic Water Level Control System using Float
Switch" project, it is evident that the fusion of ingenious hardware design and
sophisticated software logic has resulted in a transformative solution. The
successful implementation of the project stands as a testament to its feasibility
and potential to reshape the way we approach water management. By
systematically eliminating human errors and inefficiencies associated with
manual control, the project not only addresses a practical concern but also sets a
new standard for resource optimization in various sectors.

The project's significance reverberates beyond its technical achievements. It

highlights the role of technology as an enabler for sustainable practices and
showcases how even small-scale innovations can yield substantial positive
impacts.

The system worked according to specification and proved quite satisfactory. It is

relatively affordable, durable and efficient. Hence, give room for ease of
operation and high level of reliability. The system would provide a clean and
efficient way of using water for both domestic and industrial application thereby
avoiding pollution from water spillage associated with the manual control of a
water pump.

Finally, it reduces stress associated with manual water pump controller, which
require that somebody go to physically switch the pump on and off and can be
applied across residential, commercial, and industrial contexts.

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