In the 1980s, the competence of operating staff in thermal power plants was crucial for addressing issues promptly and preventing damage to valuable equipment. Effective hands-on training was imperative, and various training aids were developed, with the Operator Training Simulator (OTS) emerging as a notable example. Initially, the OTS was electromechanical, gradually evolving into fully computerised systems over time.

The development of the OTS was closely aligned with the expansion of the Trombay Thermal Generating Station. During the Trombay 4 Project, a 200 MW electromechanical OTS was created. As part of the Trombay 5 Project (500 MW), a fully computerised OTS was developed, replicating the 500 MW unit, with Tata Consulting Engineers (TCE) responsible for the software development.

The success of the Trombay 500 MW Simulator was significant, leading the National Thermal Power Corporation Ltd. (a Government of India Undertaking) to entrust TCE with the design and supply of a full replica 500 MW OTS for their Korba units on a turnkey basis. This achievement established TCE as a leading player in the field of OTS development, marking a significant milestone in the establishment of indigenous capabilities.

Globally, expertise in engineering and supplying Operator Training Simulators was limited, even in Western countries. TCE’s accomplishment in this domain represented a major leap, not only positioning the company as a leader in this specialised field but also contributing substantial economic benefits by reducing the need for foreign exchange.