Products & Solutions

World-class hydraulic engineering for critical infrastructure

01

Hydraulic Cylinders

Design and manufacture of special customized hydraulic cylinders as per Indian Standards and DIN Standards to meet specific project requirements.

Applications
  • Hydro Dam Gates, Turbines, Trash rack machines
  • Tunnel Boring machines
  • Cranes - Tower cranes, luffing cranes (Single and multistage)
  • Oil & Gas – Offshore rig Hydraulics
  • Concrete pumping machines
  • Mining equipment – Stacker reclaimers, crushers, coal handlers
  • Defence hydraulics
  • Industrial Hydraulics
Manufacturing Capabilities
  • Single-acting and double-acting cylinders with capacities up to 700 Tons and stroke lengths up to 25 meters.
  • Advanced Surface Protection: Piston rods available with Hard chrome plating, Laser cladding and Ceramic coating.
  • Premium Sealing Solutions: High-quality, long-lasting sealing systems sourced from globally reputed brands such as Freudenberg, Hallite and Trelleborg.
  • Mounting Arrangements: Trunnion, end clevis, Bonneted, Eye end, ball end, Threaded, etc.
  • Cylinders with inbuilt position measuring systems and all related accessories as required.
02

Hydraulic Power Packs

Custom-built hydraulic power packs engineered as per Indian Standards and DIN Standards to meet specific operational requirements, project / customer requirements, flow capacities, and pressure ratings.

Our hydraulic power packs are built for reliable performance, energy efficiency, and long service life in demanding industrial environments.

Applications

Our hydraulic power packs are suitable for a wide range of applications, including Hydro Dam Sector, Turbine Systems, Cranes, Tunnel Boring Machines (TBM), Stackers & Reclaimers, Earthmoving Equipment, Material Handling Systems and Heavy Industrial Machinery.

Manufacturing Capabilities
  • Oil Tank Capacity: Up to 12,000 Litres
  • Flow Capacity: Up to 500 Litres per Minute
  • Operating Pressure: Up to 250 Bar
  • Testing Pressure: Up to 300 Bar
  • Motor Capacity: Up to 130 kW

Each system is designed with careful attention to safety, efficiency, ease of maintenance and long-term operational reliability.

03

Local Control Panels & Remote-Control Panels

We design and manufacture custom-built Local Control Panels, Remote-Control Panels engineered as per Indian Standards and DIN Standards tailored to project-specific and customer operational requirements. Our electrical system is designed for reliable operation, safety, ease of maintenance and seamless integration with hydraulic and electro-mechanical systems.

Features & Manufacturing Capabilities
  • Design and manufacture of control panels for operating hydraulic power packs with motor capacities ranging from 0.75 kW to 130 kW.
  • Panels designed to control and monitor hydraulic power packs as per functional and operational requirements.
Enclosure Specifications
  • Single-door or double-door architecture
  • Aluminium or Stainless-Steel construction
  • Welded or bolted enclosure designs
  • Enclosures sourced from reputed manufacturers such as Rittal, Hoffman and equivalent global brands
  • Standard IP and NEMA ratings selected based on environmental and site conditions
  • All enclosures powder coated in RAL 7035 colour shade
Components and Instrumentation
  • Panels are equipped with high-quality components like Push Buttons, Selector Switches, Position Indicators, Voltmeters and Ammeters, PLC (Programmable Logic Control) systems programmed by NextHydro engineers. These components are from reputed manufacturers like ABB, SIEMENS, L&T, Delta etc..
Cabling and Communication
  • Cables and accessories selected based on operating criteria with appropriate safety factors
  • High-quality industrial-grade cables and accessories used for reliable performance
  • Communication between Local and Remote-Control Panels: Includes Dam Control Rooms, through:
    • Ethernet Communication
    • OFC (Optical Fibre Cable) Communication
    • Ring Network or Profibus network
  • Integration with field sensors and automation systems based on project distance and site conditions
04

Automatic reservoir monitoring and control system (ARMAC)

Our Expertise in ARMAC System for Hydro projects, specially developed by Mr.Ashok B Rao for dam safety during unforeseen flood conditions.

ARMAC system installed with SCADA, monitors the inflow and outflow of water level and calculates and decides whether the water to be stored or discharged from the dam based on storage capacity of the dam and incoming water flows.

Capabilities:
  • Automatically regulate the combined opening of the gates to control the outflow of water as required by the project authorities.
  • To change the parameters of response of the gates to the inflow levels by changing the program – PC based system allows us to do flexible programming.
  • To read position of each gate.
  • Get indications at the control panels regarding the operational and positional status of each gate, including the real-time display of gate motion of the selected gate.
  • Obtain audio / visual alarms and indications of various faults in the hydraulic systems.
  • Provide printouts at periodic intervals as stipulated by users regarding the water inflow, outflow, gate levels and fault indications.
  • To operate the gates manually by clicking the mouse button in the computer screen.
ARMAC system consists of:
  • Redundant CPU system (Hot Back-up system).
  • Operator Station, One at DCR and One at Power House (SCADA - Supervisory Control And Data Acquisition).
  • Remote Control Panel with I/O Modules.
  • Local Control Panel with CPU.
  • Indicators and Sensors.
05

Hydraulic Piping & Accessories

Design and supply of complete hydraulic piping systems and accessories connecting hydraulic cylinders to hydraulic power packs for various gate applications including radial gates, intake gates, silt flushing gates, under sluice gates and navigation locks.

The NextHydro team possesses extensive expertise in hydraulic piping design, pipe size calculation, routing and selection of related accessories based on project requirements.

Hydraulic pipes are supplied in multiple sections, typically 5 to 6 metres in length and are butt welded using the TIG welding process. Our experienced welders execute precise site welding after pipe laying, ensuring proper alignment and routing according to actual site conditions.

All piping is securely supported using heavy-duty pipe clamps mounted on structural mounting rails. These rails are fixed to clamping plates and anchored to concrete structures using high-strength anchor bolts for long-term stability and vibration resistance.

Pipe interconnections are carried out using flanges, straight couplings, PMSC fittings and tee connections. High-pressure hydraulic hoses of suitable lengths are provided for flexible connections between hydraulic piping and hydraulic cylinders.

06

Gasoline Engine power pack

NextHydro designs, manufactures and installs at site this emergency operated gasoline engine power pack.

These portable petrol engine operated power packs can be connected to any electric power pack and operated.

Gasoline Power Pack
07

Oil Cleaning and Monitoring Equipment

NextHydro offers an extensive range of hydraulic oil cleaning and monitoring equipment designed to maintain oil cleanliness and improve the reliability of hydraulic systems.

  • Our low vacuum dehydration units and electrostatic oil cleaning machines effectively remove contamination, moisture and impurities from hydraulic oil, thereby extending oil life and enhancing system performance. Different models are available to suit various flow capacities and operational requirements.
  • NextHydro also provides oil contamination checking units for accurate monitoring of hydraulic oil cleanliness. Using advanced digital instruments, the system measures oil cleanliness levels and instantly displays the NAS cleanliness level, enabling quick assessment of oil quality based on standard NAS charts.
  • In addition to advanced digital monitoring systems, we also offer conventional filter paper–based contamination testing methods, where oil cleanliness is evaluated based on the colour change of the filter paper. This provides a simple and economical solution for routine oil condition monitoring.
08

Sensors and Monitoring Systems

NextHydro provides advanced sensors for hydraulic cylinder and gate position measurement to ensure accurate monitoring and reliable operation of dam gate systems.

Depending on the gate type and application, various sensing technologies are used, including angular transmitters for radial gates, wire rope sensors for vertical gates and internally mounted Temposonic-type sensors for hydraulic cylinders. These systems provide precise gate position feedback, enabling operators to accurately identify gate conditions such as fully open, fully closed or creep movement.

We also supply and install sensors for water level measurement at dams and silt level monitoring based on specific project requirements.

All sensors can be integrated with Local Control Panels, Remote Control Systems and AMRAC systems, enabling automatic operation and monitoring of hydraulic systems based on real-time sensor inputs.