RWP - H1 Heater.pdf

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS AIR FORCE TEST CENTER (AFMC)

EDWARDS AIR FORCE BASE CALIFORNIA

Project Subject H-1 Heater Modernization

Document Type Request for Whitepapers (RWP)

Target Audience AEDC Velocity Alliance Consortium Performers and Industry

Partners via SAM.gov

Applicable NAICS Code 811310 (Commercial and Industrial Machinery and Equipment

Repair and Maintenance)

Applicable PSC Code J045 (Maintenance, Repair, and Rebuilding of Equipment)

Acquisition Authority 10 U.S.C. § 4022 Other Transaction Authority (OTA)

1.0 Introduction and Purpose

Arnold Engineering Development Complex (AEDC), is issuing this Request for Whitepapers

(RWP) to identify a qualified Performer to execute the H-1 Heater Modernization project at

Arnold Air Force Base (AAFB), Tennessee.

The existing H-1 Heater is an indirect-fired air heater that is currently over 40 years old.

Originally designed to provide intermediate temperature air to the mixing header and heated inlet air to the high-temperature H-2 Heater, the system has operated under reduced capacity for a significant period. The existing equipment is approaching the end of its expected operational life and presents critical risks regarding operational reliability, personnel safety, and regulatory compliance.

The successful modernization of the H-1 Heater is a prerequisite to supporting the addition of a new H-2 Heater (which is being provided through a separate, parallel effort). This RWP seeks whitepaper submissions from Performers demonstrating the capability to design, engineer, evaluate, and commission a fully functional H-1 Heater system that restores the system to its original design specifications.

2.0 Project Scope and Key Objectives

The modernization scope encompasses all engineering, analysis, evaluation, procurement, demolition, fabrication, installation, programming, inspection, demonstration, testing, and documentation necessary to design, deliver, and commission a fully functional H-1 Heater system. The key objectives are included in Attachment 1 – Performance Parameters.

3.0 Instructions for Performer's Response

The Performer shall submit a white paper, not to exceed 15 pages, that details, at a minimum, the following:

3.1 Technical Competency

The Performer must provide evidence demonstrating their capability to satisfy the project requirements established in Attachment 1 – Performance Parameters. Evidence shall consist of no more than three examples of successful past performance of efforts that include one or more of the following:

1. Combustion & Burner Systems: Demonstrated capability in designing and fabricating or overhauling indirect-fired industrial air heaters and multi-burner systems complying with NFPA 85 and NFPA 86.

2. Safety Instrument Systems & BMS: Experience developing and certifying SIL 3

Burner Management Systems per IEC 61508.

3. Industrial Controls Integration: Demonstrated competency programming Emerson

RX3i PLCs using Proficy Machine Edition and designing GE Cimplicity HMI systems.

4. Pressure Vessel and Piping Design: Ability to perform mechanical, structural, and fluid flow analyses, design carbon steel pressure boundaries , and fabricate systems in accordance with ASME Boiler and Pressure Vessel Code and power/process piping standards.

5. Professional Engineering Certification: Formal capability to deliver final engineering documents, drawings, and analyses stamped by a Professional Engineer (PE) licensed in the State of Tennessee.

All past experience examples shall include, at a minimum, a detailed description of the work, a description of how it is relevant to the above criteria, metrics demonstrating successful performance, and a point of contact (name, position, and contact information) for the customer.

The Performer must also provide a brief technical narrative outlining how they intend to satisfy the project requirements and adhere to the technical constraints.

3.2 Intellectual Property (IP) & Data Rights

The Performer shall explicitly state their compliance with Article: Intellectual Property Rights in accordance with part 3 of the AEDC Velocity Consortium Request for Whitepaper. The

Government requires Unlimited Data Rights to all Performer-provided technical data, analysis, drawings, software, code, and programming produced in performance of this effort. Performers must provide a formal, written confirmation in their whitepaper confirming that all prototype designs, software source codes (for PLC and HMI), and drawings will be delivered as the property of AEDC in native formats (e.g., AutoCAD, native PLC/HMI formats).

3.3 10 U.S.C. 4022(d) Appropriate Use of Authority

Pursuant to 10 U.S.C. § 4022(d), other transaction agreements for prototype projects may only be entered into if:

1. There is at least one nontraditional defense contractor or nonprofit research institution participating to a significant extent in the prototype project;

2. All significant participants in the transaction other than the Federal Government are small businesses or nontraditional defense contractors; or

3. At least one-third of the total cost of the prototype project is to be paid out of funds provided by sources other than the Federal Government.

Note: Performers must demonstrate compliance with at least one of these conditions in their whitepaper submission.

3.4 Pricing and Schedule

The Performer must structure their business proposal to align with the milestone types defined in

Section 6.0:

• Base Milestones (Prototype Type A - Proof of Concept / Business Process): The

Performer must provide firm, fixed milestone pricing and a detailed resource-loaded schedule (WBS Level 3 or better, exported in the native file format).

• Optional Milestones (Prototype Type E - Operational Utility): The Performer is not required to provide milestone pricing or a Rough Order of Magnitude (ROM) cost estimate. However, the Performer is required to provide an estimated schedule, task durations, and sequence showing how these optional milestones fit into the overall project lifecycle.

3.5 Cybersecurity and CMMC Compliance

Because the project involves Controlled Technical Information (CTI) and Controlled

Unclassified Information (CUI), the Performer must show they possess a Cybersecurity Maturity

Model Certification (CMMC) rating or equivalent safeguards. Performers must explicitly highlight that all cybersecurity requirements flow down to subcontractors and partners, and that overall compliance remains the sole responsibility of the prime Performer.

4.0 Evaluation Details

Whitepapers will be evaluated on the Performer's capability to execute the modernization of the

H-1 Heater within the constraints and performance parameters defined in the Statement of

Objectives. The Government will evaluate submissions using a Best Value determination based on the following criteria of equal importance:

1. Technical Competency and Capability: Evaluation of the Performer's demonstrated capability, engineering experience, and technical approach to meeting all mechanical, electrical, and control system requirements, including safety shutoff valve compliance, SIL 3 burner management systems, and ASME-compliant design.

2. Schedule Feasibility: Evaluation of the realism, logical sequencing, and completeness of the proposed execution schedule, particularly regarding design review gates and coordination of facility outages and road closures.

3. Cost/Price Realism: Evaluation of the completeness, realism, and alignment of the milestone pricing and estimated schedule for unpriced options with the proposed technical approach.

*Pricing Constraints – Proposal Validity:

Based on market standard practices, all Firm-Fixed Price (FFP) submissions for the

Business Process and Proof of Concept (PoC) phases (i.e., Prototype A design milestones for both the Base Requirement and all Optional Projects) must remain valid and binding for a minimum of 180 days from the date of the initial Other Transaction Prototype

(OTP) award. Rough Order of Magnitude (ROM) estimates for subsequent fabrication phases (Prototype E) are exempt from this hold but must reflect accurate market conditions at the time of submission.

5.0 Successful Prototype Definition

Success criteria are defined for each of the prototype types included in this transaction:

5.1 Prototype Type A: Proof of Concept / Business Process [Base Milestones]

• Prototype Goal: To validate the engineering feasibility, safety integrity, and controls compatibility of the H-1 Heater Modernization design before physical fabrication.

• Completion Metrics & Standards:

o Development of a complete, detailed Statement of Work (SOW) and

Requirements Traceability Document (RTD).

o Delivery of an approved Site Plan, Hazard Tracking Log, and Project Risk

Assessment.

o Approval of comprehensive engineering analyses (mechanical, structural, electrical power, and fluid flow) stamped by a licensed Tennessee Professional

Engineer.

o Delivery of detailed schematics and P&ID drawings compatible with AutoCAD, proving controls compatibility with Emerson RX3i PLCs, Proficy software, and

GE Cimplicity HMI.

o Independent safety analysis proving that the Burner Management System (BMS) achieves a Safety Integrity Level (SIL) 3 rating.

• Validation Method: Successful execution and formal sign-off (via AAFB Form 1683) of the five required design review gates: Contractor Readiness Review (CRR), Preliminary

Design Review (PDR), Critical Design Review (CDR), and Final Design Review (FDR), with all deficiencies (AAFB Form 1565) resolved or dispositioned.

5.2 Prototype Type E: Operational Utility [Unpriced Optional Milestones]

• Prototype Goal: To physically demonstrate the operational utility and performance restoration of the modernized H-1 Heater system in an operational testing environment.

• Completion Metrics & Standards:

o Continuous Heating Performance: Demonstrating capability to continuously operate at the original design point as stated in the requirements documents.

o Inlet Pressure Range: Reliable continuous operation across the inlet pressure range stated in the requirements documents.

o Pressure Differential Limit: Verification that total system pressure loss through the heater, inlet, discharge ducting, and valves does not exceed the parameters stated in the requirements documents.

o Safety Valve Timing: Proving that all safety shutoff valves (main and pilot burners) close in less than 1.0 second on loss of power or control signal.

o Thermal Guarding: Verification that all accessible surfaces within 8 ft of working areas do not exceed 120°F.

o Acoustics: Sound levels must not exceed the parameters stated in the requirements documents.

o Control Room Interface: Seamless command, feedback, and read-only safety diagnostics communication between the local PLC, the BMS, and the central

AEDC Plant Control System.

• Validation Method: Successful physical execution of the approved Verification Plan and

System Test Plan (including on-site, air-on testing in coordination with AEDC personnel), completion of training, and formal sign-off of the Verification Readiness

Review (VRR) and System Readiness Review (SRR).

6.0 Program Milestones

The execution schedule is structured into sequential milestones. Every milestone must be completed and approved by the Government to progress the program. No specific target dates are included; the Performer shall propose durations and sequencing in their whitepaper.

Milestone Type Prototype

Mapping SOW Deliverable Reference

Milestone 1:

Project Kickoff

Meeting

[Base

Milestone]

Proof of

Concept /

Business

Process

(Type A)

Statement of Work (SOW), Requirements

Traceability Document (RTD)

Milestone 2:

Contractor

Readiness

Review (CRR)

[Base

Milestone]

Proof of

Concept /

Business

Process

(Type A)

CRR Package, Project Schedule, Risk

Assessment Matrix

Milestone 3:

Preliminary

Design Review

(PDR)

[Base

Milestone]

Proof of

Concept /

Business

Process

(Type A)

PDR Package, Process System Schematics, Mechanical Drawings/Analysis, Structural

Drawings/Analysis, Electrical/Control Design, O&M Plan (Draft), Verification Plan (Draft)

Milestone 4:

Critical Design

Review (CDR)

[Base

Milestone]

Proof of

Concept /

Business

CDR Package, Finalized Site Plan, Process

System Schematics, Mechanical/Structural/Electrical Drawings &

Process

(Type A)

Analysis, Demolition Plan (Draft), Manufacturing

Plan (Draft), Installation Plan (Draft), Verification & System Test Plan (Draft)

Milestone 5:

Final Design

Review (FDR)

[Base

Milestone]

Proof of

Concept /

Business

Process

(Type A)

FDR Package (Approved State), Construction

Drawings, Final SOW & RTD, Finalized

Demolition/Manufacturing/Installation Plans, Approved Verification & System Test Plans

Milestone 6:

Completion of

Fabrication and

Installation

[Unfunded

Option]

Operational

Utility (Type

E)

As-Built Drawings, System Configuration, Demolition/Manufacturing/Installation

Completion Evidence

Milestone 7:

Verification

Readiness

Review (VRR)

[Unfunded

Option]

Operational

Utility (Type

E)

VRR Package, User Manuals, Training Material, Personnel Qualifications

Milestone 8:

Performance

Testing and

Demonstration

[Unfunded

Option]

Operational

Utility (Type

E)

Performance Testing Results, Demonstration

Results, Verification Summary, RTD (Final)

Milestone 9: On-

Site Training and Orientation

[Unfunded

Option]

Operational

Utility (Type

E)

Completed Training Records, Operational

Handoff Documentation

Milestone 10:

System

Readiness

Review (SRR)

[Unfunded

Option]

Operational

Utility (Type

E)

SRR Package, Signed AEDC-1683 indicating

Approval, Certified Modernized H-1 Heater

System

7.0 Submission Details

• Submission Deadline: 24 September 2026

• Submission Format: Electronic submission via secure portal in PDF format. Technical and Business volumes must be separated. Schedules must be attached in native formats

(Primavera .xer or MS Project .mpp).

• Government Point of Contact (POC):

Haley M. K. Smith, Agreements Officer

AFTC/PZIA (Arnold) haley.smith.10@us.af.mil

8.0 Attachments

The following reference documents govern this modernization effort:

mailto:haley.smith.10@us.af.mil

1. Attachment 1: Statement of Objectives (SOO) H-1 Heater Modernization

2. Attachment 2: Performance Parameters (Distribution D, Export)

3. Attachment 3: Appendix A – Reference Drawings (Distribution D)

4. Attachment 4: Appendix B – Design Review Expectations

5. Attachment 5: Appendix C – AEDC Standards

6. Attachment 6: Appendix D – Road Load Limits (Distribution D)

HALEY M. K. SMITH

Agreements Officer