Determining the optimized pipeline distribution network alignment is a critical component in the Engineering, Procurement, and Construction (EPC) of irrigation infrastructure, constituting 70-80% of total project costs. Traditional methods for network routing rely on manual efforts, substantial engineering man-hours, and tools like AutoCAD, often resulting in inefficiencies and prolonged timelines. To address these challenges, a novel automated routing model has been developed, integrating hydrology concepts with Dijkstra's algorithm within a Geographic Information System (GIS) environment. Dijkstra's algorithm, renowned for its least-cost path capabilities, is adapted here to account for terrain constraints such as slope, settlements, waterbodies, forests, and crossings over roads, railways, and streams.

This innovative model was validated through a case study, demonstrating its superiority over conventional methods. The automated routing produced significantly shorter pipeline lengths, reduced the number of crossings, and achieved these results in under a day compared to the weeks required by traditional approaches. Hydraulic analysis further confirmed substantial cost reductions in pipeline construction. Additionally, the integration of Lean techniques, particularly Value Stream Mapping, identified inefficiencies in the conventional routing process and highlighted the potential of geospatial technologies in eliminating waste.

A practical application in the Mega Lift Irrigation Project – Cluster XXV in Odisha, India revealed that the use of geospatial and lean methodologies enhanced productivity by over 70%. The automated process not only provided multiple optimized routing options swiftly but also contributed to a marked reduction in pipeline lengths and overall costs. This combined approach underscores the transformative potential of GIS and lean principles in revolutionizing pipeline network design for irrigation EPC projects, ensuring cost-effectiveness and accelerated project delivery.