As part of the make-up and ash water recirculation system of the Meja Thermal Power Plant, MUNPL required pipelines to convey water from the intake at the river Ganges, situated nearly 22 km from the plant. The alignment mandated a critical crossing of the Howrah–New Delhi main line of Indian Railways at Km 785/25–27, together with the proposed tracks of the Dedicated Freight Corridor (DFC).

For this crossing, the pipe pushing technique was adopted—a method that allowed pipelines to be driven beneath live railway tracks without disruption to operations. Although not part of the main railway siding works, MUNPL entrusted RITES under separate contracts with the DPR preparation, detailed engineering, and Project Management Consultancy for the execution of this assignment.

The scheme involved the insertion of two mild steel (MS) casing pipes of 1200 mm diameter each, positioned at a depth of 3.5 m below rail level. Approvals of the General Arrangement Drawing (GAD) from both NCR and DFC were obtained after multiple site inspections and consultations. The operation itself was carried out strictly in accordance with RDSO guidelines BS-105 on pipeline crossings under railway tracks.

Execution commenced with the construction of a thrust pit, from which the pipes were advanced. Two hydraulic jacks per pipe were employed to incrementally push the sections forward, with painstaking attention to alignment control and the stability of the embankment soils, thereby averting any risk of track settlement or failure.

To ensure durability and long service life, cathodic protection was provided. A sacrificial magnesium anode system safeguarded the external surfaces of the pipes against corrosion. Further, radiographic testing of every joint was performed to eliminate deficiencies and validate the integrity of the installation.

RITES not only managed the engineering but also undertook the tendering and contract finalisation, with execution awarded to M/s Creative Entrepreneurs LLP, New Delhi. The work was successfully completed in August 2018, at a completion cost of ₹98.32 lakh, exemplifying the effective application of trenchless construction techniques in a congested, operational railway environment.