The reliability of electric motor–pump systems is critical in industrial and municipal applications, particularly in water supply systems where failures lead to significant economic losses, service interruptions, and resource wastage. Vibration is one of the primary indicators of mechanical and hydraulic faults such as misalignment, imbalance, bearing defects, and cavitation. This paper proposes a low-cost IoT-based condition monitoring system for real-time detection and prevention of motor–pump faults. The system integrates multiple sensors, including vibration sensors mounted at the motor drive end, non-drive end, and pump casing, along with a current sensor and water level sensor. These sensors are interfaced with a Node MCU ESP8266 microcontroller, which enables wireless data transmission to a cloud-based platform for monitoring and analysis.

The proposed system employs intelligent decision logic to correlate vibration, current, and water level parameters for accurate fault identification, such as dry running, cavitation, mechanical looseness, and overload conditions. The system also provides automated control through relay-based switching and real-time alerts via a mobile application, such as the Blynk IoT App. The total implementation cost is less than ₹2000, making it highly suitable for low-resource environments like municipal water systems and small-scale industries. The proposed solution enhances equipment reliability, reduces maintenance costs, and prevents unexpected failures, thereby contributing to efficient and sustainable operation.